Warehouse polishing splits between open aisle slabs and the tight zones around mezzanine decks and column bases: full-size machines cover the open floor, while columns and edges need compact units and hand-held tools. The risk is reach, not finish quality: an unreachable band reads dull under warehouse light, and a deck polished past its load limit creates a structural claim. This article covers reach, edge work, load checks and acceptance; limits follow the specification.

Scope: mezzanine decks and column-base zones

Walk the warehouse with the owner rep and racking engineer before pricing: aisle slab, deck type, steel columns, toe kicks and topping. Mark every column, deck edge and rack leg on the zone drawing, noting where racking or conveyors must be protected. Surface temperature 10-30 C and RH below 75-80% are required before densifier. Decide which zones a full-size unit can reach and which need compact or hand-held tools; deck edges over a void are the usual dispute zone.

Equipment reach: compact units and hand-held tools

A standard walk-behind grinder needs roughly a 700-900 mm clear travel width; aisles between racking and columns often leave less. Plan a compact unit, 350-500 mm wide, for the 1.0-1.5 m band around columns and edges, plus a hand-held tool for the last 100-150 mm against bases. Check machine weight against the mezzanine live load before any unit goes on deck; compact heads carry lower point loads. Note power supply on each level.

• Clear width: measure aisle and column gaps before booking machines; flag gaps under 700 mm for compact or hand-held work.
• Point load: list grinder, extractor and trolley weights against the mezzanine rating before deck access.
• Edge band: reserve 100-150 mm around each base for hand-held work instead of pushing the main head in tight.
• Power: check outlets or generator placement on the deck so leads do not cross finished aisles.
• Extraction: every compact unit and hand tool runs to its own HEPA extractor; no dry sweeping in the warehouse.

Column base edge finishing and radius transition

Column bases collect dust, slurry and filler, and are the first place a dull band appears. Clean and prep the base before grinding, then run the field finish to the boundary, followed by the compact unit and hand-held tool outward. Match the grit sequence across the boundary: do not stop resin steps early, or the 100-200 grit scratch shows as a ring under raking light. Where the base has a round radius or upstand, shape a smooth transition rather than a straight cut.

Mezzanine load limits, slab thickness and substrate checks

Before polishing any mezzanine deck, confirm the substrate with the engineer: slab thickness, topping depth, steel plate and overlay, and the rated live load. Typical warehouse slabs run 100-180 mm; a thin topping over a deck can delaminate under grinding pressure, so do not assume the deck takes the ground-floor machine. Check for hollow areas and loose topping by sounding or core sample where required. Record slab thickness, machine weight and pressure per deck; if the topping is too thin, stop and agree a repair.

Joints, edges and perimeter band consistency

Control joints, penetrations and deck perimeter lines collect paste and filler; clean them after grinding and refill or seal per spec. The perimeter band where the machine cannot reach should match the field finish in gloss, not just color. Run the edge tool across joint lines in one pass so the joint does not read as a gloss break. Check one band every 10-15 m plus every base; adjacent areas differ by up to 5 gloss units, and a gap above 15 units triggers rework.

Dust control and work in occupied storage aisles

Warehouses often stay live during polishing: stock, forklifts and pickers keep moving. Seal the work zone from active aisles with sheeting on 2.0-2.4 m frames, and agree the forklift route, hours and daily clean-up with the owner rep. Keep the HEPA extractor on every machine and hand tool, clean trolley and wheels before crossing a finished aisle, and vacuum rather than sweep. Schedule loud metal phases around receiving hours, protect stock, and record a baseline walk-through before start.

Acceptance: gloss, edge appearance and slip criteria

Define acceptance before mobilization and run it zone by zone against the mock-up, at least 3 x 3 m on site. Read 60-degree gloss on a grid, one point every 10-15 m2 in the field and one check on each perimeter band and base. Inspect under 300-500 lux raking light at 15-30 degrees for rings, dull bands and streaks; photograph flagged patches with zone number. Slip checks follow the spec: dry PTV at least 36, wet PTV 10-20 lower, DCOF at least 0.42; edges and openings get the same test.

Common disputes and record-keeping

Most warehouse disputes fall into four patterns. Edge reach: the owner expects a full polished finish around columns where only hand tools fit; agree the boundary and edge method at walk-through. Load concern: a machine on a mezzanine raises structural questions; document point loads and engineer approval before deck access. Dull perimeter: caused by under-allocated edge time; match band grit and gloss to the field. Dust on stock: resolved by dedicated routes, extraction and a baseline record. Drawings, load checks and walk-throughs are the reference for later claims.