Commercial Warehouse Concrete Grinding & Floor Preparation – Campbelltown NSW

After moving into a larger commercial warehouse in Campbelltown NSW, the owner needed approximately 1,500 m² of concrete mechanically prepared before his employees installed the selected epoxy flooring system.

Our scope was the commercial concrete grinding and substrate-preparation stage only. We did not install the epoxy coating on this project. Our job was to leave the existing slab clean, mechanically open and consistently profiled so the owner's team could assess the floor and proceed with its coating installation under the requirements of the selected epoxy system.

We completed the approximately 1,500 m² warehouse floor preparation over two working days using our Husqvarna PG 6 DR remote-controlled planetary grinder, supported by dust-controlled extraction and detailed perimeter preparation.

Project overview

The concrete floor contained surface contamination and remnants of previous material in some areas. Although a warehouse slab may appear generally clean from a distance, smooth sections, weak surface material or residual products can interfere with the bond of a new coating. The floor therefore required mechanical preparation rather than cleaning alone.

Because of the size of the warehouse and the owner's programme, we needed an organised sequence that could cover the large open area efficiently without losing sight of the preparation standard. The main grinding runs, restricted perimeter work, dust extraction, cleaning and final inspection were coordinated as connected parts of the two-day scope.

Project facts

• Location: Campbelltown NSW
• Site type: Commercial warehouse
• Floor area: Approximately 1,500 m²
• Service: Concrete grinding and floor preparation
• Equipment: Husqvarna PG 6 DR
• Duration: Two working days
• Purpose: Prepare the concrete for an epoxy flooring system
• Coating installer: Owner's employees
• Our scope: Mechanical grinding and substrate preparation only

Why the concrete needed mechanical preparation

Installing epoxy over concrete that has not been properly prepared can contribute to poor adhesion, peeling, delamination and premature coating failure. A floor may look clean while still containing contamination, smooth areas, weak surface material or remnants of an earlier product that can interrupt the bond of a new coating.

The purpose of this project was not to polish the concrete or create a decorative exposed finish. We needed to mechanically remove unsuitable surface material and create an open concrete profile for the next flooring system.

The grinding pattern visible after preparation was intentional. It showed that the surface had been mechanically cut rather than left smooth, sealed or polished. That profile formed the handover condition for the owner's epoxy installation team.

Initial warehouse floor inspection

Before beginning production grinding, we inspected the accessible warehouse floor and reviewed the overall condition of the concrete. We identified surface contamination, residual material, inconsistent texture and areas that could require additional attention as the work progressed.

We also planned the general direction of the grinding runs so we could work systematically across the large open floor while coordinating the main grinding area, perimeter work, dust extraction and cleaning. Planning the sequence was especially important because the complete preparation scope had to be delivered over two working days.

Large-area grinding with the Husqvarna PG 6 DR

We used our Husqvarna PG 6 DR remote-controlled planetary grinder for the main warehouse floor. The machine was operated in planned, overlapping runs across the slab to avoid leaving untreated strips between adjacent paths.

Remote operation allowed us to monitor the grinder's movement and the changing condition of the concrete from different positions rather than remaining directly behind the machine for the entire process. Across a large open warehouse, this helped us maintain an organised grinding pattern and assess the consistency of the prepared surface while working to the programme.

The Husqvarna PG 6 DR mechanically cut the surface of the concrete, addressed unsuitable surface material and opened the slab. Where an area did not show a consistent preparation profile, it was inspected and worked again as required before acceptance for handover. We have more information about this type of work on our commercial concrete grinding and floor preparation page.

Dust-controlled commercial grinding

Commercial floor grinding produces fine concrete dust, so dust management formed an important part of the project. Extraction was used with the grinding equipment to capture material close to the grinding heads.

This helped keep the active work area more controlled, maintained visibility of the slab and reduced the amount of loose dust left across the warehouse. Dust-controlled grinding does not mean no dust is produced. It means suitable extraction, cleaning and work practices are used to manage the dust generated during mechanical preparation.

Detailed edge and perimeter preparation

The main planetary grinder could prepare most of the open warehouse floor, but it could not reach directly against every wall, column, doorway or fixed perimeter. These restricted sections required separate attention so the preparation did not stop short of the edges.

We completed detailed perimeter preparation and blended those areas back into the main floor wherever accessible. Correct edge preparation matters because a coating can be compromised around walls and transitions if the centre of the slab has been prepared but the perimeter remains smooth or contaminated.

Final cleaning and inspection

After grinding, we removed loose concrete dust and grinding residue from the floor. We then inspected the slab for visibly glossy areas, inconsistent preparation, remaining surface material and sections requiring further attention.

Any areas that had not reached a suitable mechanical profile were addressed before handover. The final surface was not presented as a polished, sealed or decorative concrete floor. It was delivered as a mechanically prepared substrate for the owner's employees to complete the epoxy installation.

Approximately 1,500 m² completed in two working days

We completed the approximately 1,500 m² commercial warehouse floor-preparation scope over two working days. Delivering a floor of this size within the programme required suitable commercial equipment, an organised grinding sequence, coordinated dust extraction and consistent machine operation.

The objective was not simply to cover the floor quickly. We needed to maintain an even preparation standard across the large area so the coating team did not inherit untreated or inconsistent sections. The completed slab was left mechanically open and ready for the owner and his employees to assess before beginning the next stage under the instructions for their selected epoxy system.

Handover for the owner's epoxy team

Resin Me Epoxy did not install the epoxy coating on this project. We completed the specialist concrete grinding and floor-preparation work, then handed the slab over for the owner's employees to install their selected coating.

In this context, “ready for epoxy” means the concrete was mechanically prepared for the next stage of work. Preparation alone does not guarantee the performance of the owner's coating. The installer still needs to confirm that the slab condition, moisture level, cleanliness, environmental conditions and surface profile meet the coating manufacturer's requirements before application.

This division of work allowed the owner's team to focus on its epoxy application while we handled the heavy mechanical preparation and large-area grinding. For clients who want both stages completed by one contractor, our commercial epoxy flooring service covers system selection and coating installation as a separate scope.

Project outcome

The warehouse owner received a mechanically prepared concrete substrate without needing to purchase or operate large commercial grinding machinery. Our completed scope included:

• Approximately 1,500 m² of concrete mechanically ground
• Commercial floor preparation completed over two working days
• Surface contamination and residual material addressed during preparation
• Main floor prepared using the Husqvarna PG 6 DR
• Perimeters and restricted areas given separate attention
• Loose concrete dust and grinding residue removed
• Slab inspected before handover
• Floor prepared for the owner's employees to install epoxy

The result was intentionally a prepared working surface, not a finished decorative floor. The grinding marks and open concrete profile were part of the required handover condition.

Why preparation matters before epoxy

Epoxy flooring depends heavily on the condition of the concrete beneath it. Even a suitable coating product can perform poorly when installed over contamination, weak surface material, smooth concrete or an incompatible existing coating.

Mechanical concrete preparation creates a direct physical profile in the slab. This gives the coating a more suitable surface to bond to and helps reduce the risk associated with inadequate preparation. The exact method required on another site will depend on the slab, the material being removed and the flooring system that follows.

A site inspection is normally required before confirming equipment, tooling, production rate and preparation specification. The two-working-day timeframe achieved here was specific to this warehouse and should not be treated as a universal rate for every 1,500 m² floor.

Commercial concrete grinding capability

This Campbelltown warehouse project demonstrates our ability to deliver large-area concrete grinding under a tight programme while maintaining attention to dust management, edges, floor consistency and the required handover condition.

We provide commercial concrete grinding and floor preparation across Sydney for warehouses, factories, workshops, retail tenancies, distribution facilities, commercial fit-outs, end-of-lease projects, industrial refurbishments and floors that require coating or adhesive removal.

Preparation can be completed as a standalone service for builders, flooring contractors, business owners and clients who have arranged for another team to install the compatible flooring system. More examples are available in our completed project gallery.

Frequently asked questions

Why was the warehouse floor ground before epoxy?

Mechanical grinding removes unsuitable surface material and creates an open profile in the concrete. This helps the epoxy bond to the slab more effectively than it would over smooth, contaminated or inadequately prepared concrete.

How long did the 1,500 m² warehouse preparation take?

We completed the approximately 1,500 m² floor-preparation scope over two working days. Timeframes for other warehouses depend on the existing coating, contamination, concrete hardness, access, edges and the preparation standard required.

Did Resin Me Epoxy install the epoxy coating?

No. Our scope on this project was the commercial concrete grinding and floor preparation. The owner's employees were responsible for installing the selected epoxy system after handover.

What equipment was used for the warehouse grinding?

The main floor was prepared using a Husqvarna PG 6 DR remote-controlled planetary grinder. Separate equipment and methods were used to address perimeter and restricted sections where the main machine could not reach.

Can concrete grinding be completed as a standalone service?

Yes. We can complete concrete grinding and surface preparation for builders, flooring contractors and business owners who have arranged for another team to install the final coating or flooring system.

Planning a commercial floor-preparation project?

If your warehouse, factory or commercial floor needs mechanical preparation before epoxy or another compatible system, send us the approximate area, site access information, photographs of the existing surface and the requirements of the flooring product that will follow. Request a site inspection or project quote.

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