Case Study 1 - Kaizen Industrial Group

Client: Prologis

Main Contractor: Glencar Construction

Scope of Work: Concrete joint repair, bolt hole filling, and 7-stage concrete polishing

Project Overview:

Kaizen Group was engaged by Glencar Construction to undertake comprehensive concrete refurbishment works at a Prologis-owned warehouse. The project encompassed the repair of deteriorated floor joints, the removal and filling of 19,000 anchor bolt holes, and the application of a 7-stage concrete polishing process to the entire facility.

Efficient Execution:

Our team meticulously cut out and replaced old floor joints with high-quality materials designed to outlast the floor itself. The process involved removing damaged concrete, preparing the joint edges, and filling with durable repair mortars. This approach ensured structural integrity and longevity.

The removal of 19,000 anchor bolts, previously used for racking installations, was a significant undertaking. Each hole was drilled out, filled with a robust epoxy compound, and ground flat to restore the floor’s smoothness and functionality.

For the final touch, we executed a 7-stage concrete polishing process, enhancing both the aesthetic appeal and durability of the warehouse floor. This multi-step procedure involved:

Surface Preparation: Cleaning and removing any existing coatings or contaminants.

Grinding: Using coarse diamond abrasives to remove imperfections and level the surface.

Honing: Progressing to finer abrasives to smooth the surface and prepare for polishing..

Densifying: Applying a chemical hardener to the concrete to increase its density and durability.

Polishing: Using progressively finer diamond pads to achieve a high-gloss finish.

Sealing: Applying a protective sealant to enhance stain resistance and ease of maintenance.

Final Inspection: Ensuring uniformity and quality across the entire floor area.

On-Budget Delivery:

Despite the project’s complexity, Kaizen Group adhered strictly to the agreed-upon budget. Our efficient project management, skilled workforce, and strategic planning minimized downtime and material wastage, ensuring cost-effectiveness without compromising on quality.

Client Benefits:

Prologis experienced several advantages from choosing Kaizen Group for this project:

Enhanced Durability: The high-quality materials and meticulous workmanship extended the lifespan of the warehouse floor.
Improved Aesthetics: The polished finish provided a clean, modern appearance, reflecting positively on the client's brand.
Operational Efficiency: The smooth, level surface facilitated easier movement of goods and equipment, potentially reducing maintenance costs.
Long-Term Cost Savings: The durable repairs and finishes reduced the need for frequent maintenance and repairs, offering significant savings over time.

Conclusion:

This project underscores Kaizen Group’s capability to deliver complex concrete refurbishment works efficiently and within budget. Our collaboration with Glencar Construction and Prologis resulted in a high-quality outcome that met all client expectations and enhanced the operational efficiency of the warehouse.