Warehouse Floor Sealing and Facility Maintenance Project
1
Units Serviced
Zero dock door breakdowns in 18 months (was 2-3 per month)
Time Saved
$32,000 annually in energy savings and reduced equipment failures
Cost Savings
🔧 The Challenge
A 40,000 sq ft distribution center had severely deteriorated concrete floors from forklift traffic and heavy pallet loads. The unsealed concrete was creating dust that contaminated inventory and affected air quality for the 45 warehouse employees. The facility also needed dock door repairs, lighting upgrades, and a preventive maintenance program for its HVAC and loading dock equipment. Operations could not be interrupted, as the facility operated 6 days per week.
💡 Our Solution
Auxi developed a phased approach. The warehouse floor was sealed in 4 sections over 4 weekends, with each section completed and cured before the next workday. A fast-curing industrial epoxy sealer was used that could handle forklift traffic within 24 hours. Dock door repairs, LED lighting upgrades, and HVAC preventive maintenance were completed during operating hours in non-traffic areas. An ongoing preventive maintenance program was implemented with quarterly HVAC service, monthly dock door inspections, and annual floor resealing of high-wear areas.
✅ The Outcome
The warehouse floor dust problem was completely eliminated, improving air quality and inventory protection. The LED lighting upgrade reduced energy costs by 40 percent for warehouse lighting. All 6 dock doors were repaired and placed on a preventive maintenance schedule, eliminating the 2-3 dock door breakdowns per month that had been disrupting shipping schedules. Employee complaints about facility conditions dropped to zero. The preventive maintenance program has prevented any major equipment failures in the 18 months since implementation.
Project Photos
"The floor sealing alone solved our biggest inventory contamination issue. But the real value has been the preventive maintenance program — we have not had a single dock door failure since Auxi took over. That reliability is worth more than the cost savings."
— Operations Manager, Distribution Center
Project Details
AI-Powered Analysis
Our AI analyzed this project's results to surface key takeaways and actionable recommendations.
Optimizing Operational Budgets Through Preventive Maintenance
By proactively addressing equipment degradation, the client achieved a $32,000 annual reduction in costs. This was driven by a 40 percent energy efficiency gain and the total elimination of costly emergency repairs for loading dock doors.
Minimizing Downtime With Phased Project Execution
Auxi successfully executed a major floor renovation by dividing the 40,000 sq ft space into four weekend phases. This strategy allowed the facility to maintain its six-day production schedule without disruption to daily operations.
Prioritizing Infrastructure Health For Employee Productivity
This case study demonstrates that addressing facility environmental factors like air quality and lighting has a direct impact on workforce satisfaction. Eliminating maintenance-related disruptions ensures consistent output and removes employee complaints regarding site conditions.
AI-generated analysis for reference only. Contact our team for a tailored operational assessment.
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