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Belzona® Saves Time In A Battery Station



General Industry (GIND)



Floor Problem Areas (FPA)


Customer Location:

Duncan, Oklahoma, USA


Application Date:

February 2015


Application Situation:

Battery station for a million square foot distribution warehouse that operates 24/7.



The main path for the current battery forklift was worn to the point where the lift could no longer be used to exchange charged batteries onto the forklifts. The worn pathways were 1/2" to 3/4" deep and 6" wide from the existing elevation. Due to extreme wear from the battery forklift and acid spills on concrete, the 6" wheels had created ruts in the existing concrete, causing damage to the battery forklift that required monthly repairs. The objective was to rebuild 8" wide runways for the battery forklift and provide a protective coating for the Battery acid from runways.



 Belzona 4131 (Magma-Screed)

 Belzona 5811 (Immersion Grade)





Application Method:

The application was carried out in accordance with Belzona Know-How System Leaflet FPA-1 and FPA-3.


Belzona Facts:

The worn battery forklift runways were widened and rebuilt with Belzona 4131 and the surrounding concrete substrate was coated with Belzona 5811 to prevent further battery acid corrosion to concrete. Other products were used to rebuild track runways but quickly failed. The traditional repair option was to cut out concrete and replace. The repair estimated to cost an average of $75,000 and take 28 plus days of shutdown. Note: the cost wasn't the issue as much as the downtime. The Belzona solution provided a cost savings of $58,000 and reduced  downtime by 25 days when compared to the traditional repair method. Actual downtime: this project was completed on a scheduled weekend shutdown for other repairs within the facility.


Photographs Description

  1. Battery forklift in place
  2. Battery forklift removed; full view of battery station
  3. 8" battery forklift runways being rebuilt with Belzona 4131
  4. Completed project before battery forklift was reinstalled
Case study pic one


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