Blog Post

Wet Warehouse Floors in Atlanta

  • By 7016754621
  • 03 May, 2019

How To Avoid "Sweating Slab Syndrome" and the Associated Risks

Wet Concrete Floors

In metro Atlanta, as well as throughout Georgia and most of the Southeast, many warehouses and industrial properties struggle with wet concrete floors. This is frequently referred to as “sweating slab syndrome”. Wet warehouse floors and industrial floors create serious hazards for people, machinery, and investors. Wet concrete floors can lead to serious and costly slip and fall accidents. Slip and falls are the number one cause of workers compensation claims. Furthermore, they are the main cause of injury resulting in lost days from work. Forklifts, handling equipment, racking, and inventory can become damaged. We have worked on sites where wet, slippery floors have resulted in a loss of traction and the two forks of a lift truck actually penetrated an office wall. Fortunately, the occupant was not injured. In another instance, a lift truck was not able to stop and crashed into a demising wall. It shifted the wall and resulted in extensive damage to inventory in the adjacent unit. One of our clients even had a lift truck that slid out a dock door and crashed onto its side in the parking lot.

Causes of Wet Concrete Floors

  There are a number of contributing factors that can come together and result in wet concrete floors or “sweaty slab syndrome”. Weather is a major factor causing condensation to occur and moisture to accumulate on concrete slabs. This most often occurs in the spring when warm moist air enters a warehouse through dock doors and other openings. Most warehouses and industrial buildings are not air conditioned. Consequently, the air inside warehouses will adjust to outside temperature rapidly while the dense thermal mass of the concrete floor is much slower to change. The result is that when warm, moist air contacts the cooler concrete floor, condensation is created, and moisture accumulates on the concrete slab’s surface. This condensation occurs when warm, moist air is cooled to the dew point. For example, if a warm front with 80 degrees Fahrenheit ambient air temperature and 80% relative humidity has air that contacts a concrete slab at 73 degrees Fahrenheit, condensation will occur.

Years ago, concrete floors were finished with “wood bull floats”, resulting in a much more porous surface than modern concrete floors. As a result, in the past, porous floors were able to absorb moisture much like a sandstone coaster and provided traction. However, today most concrete floors are densely steel troweled with powerful machinery. This creates a tight surface that does not readily absorb water. Consequently, any surface moisture will “bead up” much like condensation on an enamel or metal beverage coaster.

Frequently, the accumulation of moisture on a concrete floor, or “sweaty slab syndrome”, varies significantly within a warehouse or industrial building. Often, the perimeter of the floor is dry while the rest of the building has a wet floor. This frequently occurs in modern “tilt up” buildings. “Tilt up” construction requires the concrete floor of the building's perimeter to be poured and finished at a later date than the rest of the building's floor. Frequently, it is not trowel finished as densely as the rest of the floor and has a more porous surface. This porous surface more readily absorbs moisture and stays drier than the rest of the slab.

Vapor barriers play a huge role in preventing or minimizing “sweaty slab syndrome” or wet concrete floors. Vapor barriers are plastic membranes placed on the ground before concrete floors are poured and finished. They are intended to prevent or reduce the upward transmission of moisture vapor through a concrete slab.

It may seem counterintuitive that moisture could rise up and pass through a thick concrete floor. Yet it does, and it can be a major problem. Concrete is actually very porous and, when magnified, tiny capillaries are revealed that run vertically to the floor’s surface. Moisture vapor in the soil has a tendency to migrate upward through concrete slabs when a properly functioning vapor barrier is not present. Variances in atmospheric pressure can be a significant factor in the upward rise of moisture vapor. As this moisture vapor migrates to the surface of the concrete floor it carries with it mineral salts and other impurities within the concrete slab. When the moisture evaporates, the impurities are left on the surface and result in a white colored residue known as efflorescence. Unfortunately, this is not just a cosmetic problem. Efflorescence, or salt deposits are hygroscopic in nature. Consequently, they absorb and hold on to moisture in the air. Thus, a lack of a vapor barrier can significantly contribute to wet concrete floors and sweaty slab syndrome. Routine cleaning of the floor with a floor scrubber using water and detergent can help remove efflorescence and reduce moisture accumulation.

Many buildings in metro Atlanta only have properly functioning vapor barriers under part of the slab. This can occur when the vapor barrier is damaged during construction before or during the placement of the concrete floor. The vapor barrier can be punctured, accidently or on purpose.

You might ask why would someone puncture the vapor barrier on purpose during construction?   The answer is that they want to leave work earlier than they could otherwise by expediting the removal of “bleed water” from the surface.

When a cement floor is poured, water is added to the mix to make it pliable. This water is often called the “water of convenience”. As the aggregate and other particles of the mix settle to the bottom of freshly placed concrete, the “water of convenience” or excess mixing water is pushed to the top of new slab. This water, which results during concrete placement is commonly known as “bleed water”. A very basic and fundamental rule of concrete construction is that a newly placed slab should never be steel troweled or “floated” before the bleed water evaporates from the surface. When fresh concrete is troweled or finished while bleed water is still on the surface, the new floor is likely to have a variety of problems such as diminished abrasion resistance, cracking, dusting, and lower density. Rather than wait for the water to evaporate, workers sometimes use steel rods to puncture the vapor barrier and allow the water to sink into the soil below the slab. Unfortunately, in such instances the vapor barrier has been permanently damaged.

Additionally, some contractors have a standard practice of only placing vapor barriers below the slab in areas where offices are anticipated to be constructed. Often, with new spec buildings, the vapor barriers are only placed from the “store front” to the first column back. This occurs frequently throughout Metro Atlanta and can lead to major moisture related problems. The high costs of the resulting industrial accidents and remediation costs generally far exceed the dollar savings of omitting vapor barriers.

Dealing with moisture issues on warehouse floors is more difficult than dealing with moisture in office areas. In finished offices spaces, HVAC systems generally prevent moisture from accumulating on the surface of the flooring. However, moisture vapor may rise up through a slab without a properly functioning vapor barrier and accumulate under file cabinets and furniture or cause serious issues under flooring such as VCT and linoleum. These moisture issues are usually best addressed with negative side moisture remediation barriers.

However, with warehouses it is often cost prohibitive to install negative side remediation floor systems or air conditioners. Large fans circulating air can help to reduce temperature differences at the slab surface. However, because of racking and inventory, it is often difficult to get adequate air movement along the slab. None-the-less, horizontal air movement provided by fans across the surface of the slab can be very effective in controlling moisture accumulation on floors. This is similar to air flow around a moving car preventing dew from accumulating. However, when the car is parked and its temperature reaches the dew point moisture will bead up on the vehicle.

Southeast Sealing, Inc. helps our clients manage sweating slab syndrome. We do this by installing the BYAL Floor System. The BYAL floor system was developed to help manage “Sweating floor syndrome” by improving traction and minimizing the accumulation of surface moisture. This is achieved by mechanically abrading the slab surface and applying a unique proprietary penetrating water based solution that chemically reacts within the concrete slab.

The combination of increased surface texture and the application of CCS 3300 results in improved safety and lower maintenance costs. The chances of slip and falls are reduced. Additionally, equipment such as forklifts and personnel carts,= operate more safely and reliably.

Modern concrete slabs are usually steel troweled with a smooth and dense surface. The BYAL system uses mechanical abrasion to add texture and porosity. This increases traction. Additionally, surface moisture resulting from condensation is more readily absorbed by the concrete. The abrading process also serves the purpose of removing efflorescence and surface contaminants such as soluble salts and dirt. CCS 3300 is designed to penetrate deep within the concrete slab. By means of chemical reaction it becomes an integral part of the concrete itself. While remaining “breathable”, it fills capillaries and tiny pores, thus slowing effervescence and the migration of moisture and mineral salts to the surface. Salt deposits are undesirable because they attract and retain moisture from the atmosphere as well as from within the slab itself.

Routine cleaning and maintenance of the floors is important to reduce the accumulation of efflorescence. Also, on occasions when moisture does accumulate, a wet, clean floor is much less slippery than a wet, dirty floor.

By 7016754621 13 Apr, 2023

Above are photos of our 1980s fleet of Tennant 527 and 528 floor scrubbing machines. Although long since retired and replaced, these concrete floor cleaning machines served our clients in warehouse and manufacturing facilities in the Fulton Industrial District, Marietta, Kennesaw, Decatur, Norcross, Gwinnett County, as well as throughout the Southeast.

By 7016754621 12 Dec, 2019

Thursday, December 12, Southeast Sealing attended the 20th Annual Prologis Holiday Event. Prologis provides logistics real estate solutions to the world and are leaders in the industrial real estate manufacturing industry. Southeast Sealing has been providing services including warehouse floor cleaning, coating, sealing, and joint repair to name a few for Prologis for decades. We are very proud to be one of their go-to flooring contractors. Each year at their Holiday Event, Prologis makes an effort to provide fundraising for a charitable organization. This year, they contributed to Easter Seals North Georgia. This organization was founded to provide therapy to children rehabilitating from polio. Since then, the organization has expanded its services to meet the needs of children with disabilities and other special needs living in North Georgia. Prologis collected donations, gift cards, toys, and other needed items for the children of Easter Seals. The annual Holiday Event is always a great way to catch up with fellow contractors and vendors and also to meet new people. This year, Southeast Sealing even won some beautiful boxes full of treats during a raffle!  

By 7016754621 20 Nov, 2019

Over the weekend of October 3-5, 2019, Michael attended the ARDEX Americas LevelMaster Elite 25th Anniversary trip to Miramar Beach, Florida. ARDEX hosted the event at the Hilton Sandestin, and provided a fun weekend full of networking, food, and fun in the sun (like a deep sea fishing trip).

By 7016754621 16 Sep, 2019

It came as no surprise that Southeast Sealing, Inc. was once again honored by Associated Builders and Contractors (ABC) of Georgia with a Platinum Level Safety Training and Evaluation Process (STEP) award as well as the Georgia Safety Award of Excellence. Southeast Sealing, Inc. continues to achieve these levels of safety excellence awards year after year, and we are so grateful for our team and our crew’s continued efforts. The STEP award recognizes member companies that employ effective safety practices on their job sites. Southeast Sealing, Inc. has won this award every year for over 25 years. STEP companies are up to 770 percent safer than non-STEP companies with total recordable incident rates as much as 87 percent lower. Georgia Safety Awards of Excellence are awarded to companies who have had no employee fatalities, with lost time and DART rates half the national average or less. Southeast Sealing, Inc. takes pride in our continued efforts toward maintaining the safest operations.

By 7016754621 16 May, 2019

 Back in the day, Southeast Sealing Inc. would take the crew to Mexico Beach, FL for a fishing trip to thank them for a year of jobs well done. They would board a fishing boat named Charisma and spend the day at sea. The fish they caught were taken to a local restaurant, prepared, and served to the crew for dinner.

By 7016754621 08 May, 2019

Southeast Sealing, Inc. recently completed a project just south of Metro Atlanta in the McDonough, GA area. Our customer wanted a battery charging area in their warehouse, where they could charge large batteries without worrying about acid spills on the floor. Check out the step by step process below: 

By 7016754621 26 Mar, 2019

Southeast Sealing, Inc. has been a certified Ashford Formula installer for over 35 years. We have installed Ashford Formula flooring all over the United States.

Ashford Formula is a chemically reactive liquid that penetrates the concrete, solidifying the concrete surface components into a solid mass. It produces a permanently denser, harder, penetration and abrasion resistant concrete surface. Ashford Formula is inorganic, nontoxic, VOC free, colorless and odorless.

 

·        Ashford Formula densifies concrete surfaces into a solid mass by penetrating the concrete and chemically filling the pores from within.

·        Ashford Formula chemically hardens the concrete surface, increasing the abrasion resistance by 32%.

·        Ashford Formula reacts immediately, chemically stabilizing the finished concrete surface. It also accelerates and enhances hydration of the   portland cement, helping the concrete reach its design properties.

·        Application of the Ashford Formula is a one-time, permanent application. This eliminates the need for expensive re-application materials,   labor costs and facility downtime. Routine surface cleaning is all that is required for long-term maintenance.

·        Ashford Formula combines with calcium hydroxide, becoming an integral part of the concrete, thus completely dust-proofing the surface.   This reduces maintenance costs and protects inventory and equipment from concrete dust.

·        Over time, Ashford Formula treated floors will develop a permanent and attractive sheen. Rather than eroding with traffic, the floor surface   actually begins to self polish. Note: Open or porous surfaces, or floors with poor surface integrity may not achieve these results.

 

By 7016754621 31 Jan, 2019

 Maintaining clean warehouse and industrial floors is important for a number of reasons. Most importantly, a clean floor is a safer floor. Keeping a floor free of dust, dirt, and petroleum fluids will promote a healthier work environment. Safety is greatly improved by reducing the possibility of slip and fall accidents.

 

Secondly, a clean floor contributes to better employee morale. When employees see that management takes care of their facility they take note. A clean floor reflects light better and brightens the work environment. A brighter workplace is a safer and overall more positive workplace.

 

Thirdly, a clean floor will enhance your facility’s image. Clean and well maintained floors are often an important marketing tool that will help you covey a commitment to quality in everything you do. Also, clean floors reduce dust and help to avoid dirty boxes and product reaching your customers.

 

Sensitive machinery, electrics, etc. can also benefit from keeping warehouse and industrial floors clean. Dust collecting on the floor can harm these machines, so keeping them dust-free will help preserve them.

   

By 7016754621 17 Jan, 2019
This image was taken in the late 1970s of a Tennant 520. This ride-on floor scrubber had an air cooled engine and was groundbreaking in the cleaning of industrial and warehouse concrete floors.

While this machine has been long since retired, Southeast Sealing, Inc. still utilizes Tennant's latest machines and scrubbers.  
By 7016754621 03 Jan, 2019
Subj: Replace Reflective Floor Coating, Hangar bay, Building No. 82, Naval Air Station, South Weymouth, MA

Gentelmen:

The highly professional and cooperative manner demonstrated by Southeast Sealing Engineers under the subject contract is evidenced by your willingness to make changes to the layout of the coating to provide maximum useability, without delays to the swiftness in which the coating was applied. Your personnel's dedication is evident by their insistence on covering every blemish to the complete satisfaction of the Government. 

Southeast Sealing Engineers performance and attitude throughout this contract are commended.

Very truly yours

N.F. Zeoli, JR.
LT, CEC, USN
Officer in Charge of Construction 
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