Horizontal Restoration Assessment Guide
Complete methodology for evaluating floors, decks, loading docks, and horizontal traffic surfaces in commercial and industrial facilities.
Horizontal Restoration Overview
Horizontal surfaces bear the brunt of traffic, equipment loads, and environmental exposure in commercial and industrial facilities. Deterioration affects operations, safety, and can damage expensive equipment. Regular assessment enables planned maintenance that minimizes operational disruption.
Equipment Impact
Floor defects cause $50K-$200K annually in forklift maintenance
Safety Risk
Trip hazards cause 25% of workplace injuries
Assessment Frequency
Annual inspection recommended for high-traffic areas
Surface Types
Concrete Slabs
Life: 25-50 yearsElevated Decks
Life: 20-40 yearsCoated/Sealed Floors
Life: 5-15 years (coating)Industrial Toppings
Life: 15-25 yearsCommon Defects
Joint Deterioration
HighSpalling, raveling, or failure of control and construction joints
Causes: Traffic impact, Poor joint design, Filler failure, Moisture infiltration
Impact: Accelerated slab damage, trip hazards, equipment damage
Surface Cracking
Medium-HighLinear or pattern cracking in slab surface
Causes: Shrinkage, Structural loading, Settlement, Thermal movement
Impact: Water infiltration, progressive deterioration, aesthetic concerns
Slab Settlement/Heave
HighUneven surfaces from subgrade issues
Causes: Soil consolidation, Poor compaction, Frost heave, Erosion
Impact: Trip hazards, drainage problems, equipment operation issues
Surface Wear/Dusting
MediumAbrasion of surface paste, exposing aggregate
Causes: Traffic abrasion, Poor finishing, Weak surface, Chemical exposure
Impact: Dust generation, reduced durability, appearance
Coating Failure
MediumDelamination, peeling, or wear of applied coatings
Causes: Moisture vapor, Surface prep failure, Chemical attack, Mechanical damage
Impact: Loss of protection, contamination risk, re-coating required
Loading Dock Assessment
Loading docks experience concentrated wear from truck traffic, leveler operation, and material handling. They are critical to operations and require focused assessment.
Dock Levelers
- Lip condition
- Hydraulic function
- Deck plate wear
- Hinge pins
- Safety features
Approach Aprons
- Slope/drainage
- Surface condition
- Joint condition
- Settlement
- Edge protection
Dock Bumpers
- Bumper condition
- Mounting security
- Height alignment
- Compression
Truck Wells
- Drainage
- Wall condition
- Safety railings
- Lighting
- Step condition
Interior Staging
- Floor condition
- Joint filler
- Traffic markings
- Bollard protection
Warehouse Floor Evaluation
| Test | Standard | Description | Acceptable |
|---|---|---|---|
| Flatness/Levelness (FF/FL) | ASTM E1155 | Measures surface flatness and levelness for forklift and rack operations | FF35/FL25 minimum for rack storage; FF50/FL30 for very narrow aisle |
| Joint Width Survey | Visual/Measurement | Measures joint opening to assess filler needs and slab movement | Joints <3/8" with functional filler |
| Crack Mapping | Visual Survey | Documents location, width, and pattern of all cracks | Hairline cracks acceptable; >1/8" width requires repair |
| Surface Hardness | ASTM C805 (Rebound) | Measures surface strength and durability potential | Rebound number >35 for heavy-duty use |
| Moisture Testing | ASTM F2170 (RH) | Measures internal relative humidity for coating compatibility | <75% RH for most coatings; <80% for epoxy |
Pedestrian Areas
ADA Compliance
- • Maximum 1/4" vertical changes without treatment
- • Slopes ≤2% cross-slope, ≤5% running slope
- • Firm, stable, slip-resistant surfaces
- • No abrupt level changes or trip hazards
Safety Considerations
- • Slip resistance (CoF ≥0.5 wet)
- • Trip hazard identification
- • Proper drainage to prevent ice
- • Adequate lighting for visibility
Repair Options
| Method | Cost | Life | Description |
|---|---|---|---|
| Joint Repair/Refill | $2-$5/LF | 3-7 years | Remove failed filler, clean, and install new semi-rigid or flexible filler |
| Crack Injection | $5-$15/LF | 10-15 years | Epoxy or polyurethane injection to restore structural integrity |
| Partial Depth Repair | $15-$30/SF | 10-20 years | Remove deteriorated surface and overlay with repair mortar |
| Full Depth Repair | $25-$50/SF | 20-30 years | Remove and replace full slab section for severe damage |
| Surface Hardener | $0.50-$1.50/SF | 10-20 years | Densifier/hardener to strengthen and dustproof surface |
| Resinous Coating | $3-$12/SF | 5-15 years | Epoxy, urethane, or MMA coating for protection and aesthetics |
| Slab Jacking | $5-$15/SF | 10-20 years | Polyurethane or grout injection to raise settled slabs |
Assessment Checklist
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