Distribution and plant floors

Warehouse coatings follow the slab joints

A warehouse floor estimate starts at the joints and the coating schedule, not at the building area. Forklift lanes, a battery-charge room, a cooler, and the office mezzanine are different surfaces even when they sit on one slab.

Map the slab before the coating

Record joint spacing from the structural drawings. A joint filler specified for the traffic aisle is a linear-foot item. Random cracking is not a quantity you can see on a new-building plan.

Saw-cut or construction joints in linear feet
Joint filler only where the spec requires it
Penetrations, bollards, and dock equipment deducted or detailed, not guessed
Dock pits and ramps as their own surfaces

Worked joint-filler length

Illustrative bay. Confirms that joint length is not a percentage of area.

Bay 200 ft × 120 ft = 24,000 sq ft. Joints drawn at 15 ft on center in both directions.
Lines parallel to the 200 ft side: (120 ÷ 15) − 0 if you are counting interior lines only. Interior intervals: 120/15 − 1 = 7 lines × 200 ft = 1,400 ft.
Interior lines the other way: 200/15 − 1 = 12.33 is not a valid grid. Use the dimension the structural sheet actually shows. Do not force a round module the drawing does not have.
When the sheet shows 13 lines × 120 ft, that is 1,560 ft. Total interior joint length is then 2,960 ft, before construction joints at the bay edges.

Coatings are kits and coats

A primer, a build coat, and a topcoat each have a coverage rate on the product data sheet. Multiply area by the number of coats only when the system says to, and keep the kit size in the order so leftover partial kits are visible. A sealer is not an epoxy build coat.

Offices inside the warehouse are a different floor

The pick-module office, the restrooms, and the break room usually leave the resin system. Measure them from the finish schedule so the resin area is not the gross footprint.

Related reading: resinous systems, polish sequence, slab scope.

Questions this page answers

Is a polished slab the same takeoff as an epoxy plant floor?

No. Polishing is a sequence of grinds on the concrete. An epoxy or urethane-cement system is a coating build. They can occur in different rooms of one warehouse and should be separate lines.

Do you deduct rack pads?

Deduct or detail only what the documents exclude from the coating. A note that says “coat under racking” means you do not deduct the rack footprint.

Request a joint and coating schedule

Send the current drawings, finish schedule, and the quantity format you need. The quote confirms fee, delivery date, and exclusions.

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