Case Study: Magna Manufacturing

The Challenge

Magna needed new flooring across their assembly line aisles and production areas, but shutting down production wasn't an option. The facility runs continuous shifts Monday through Friday. We had to deliver a durable, commercial-grade coating system in 48-hour weekend windows.

Before committing to the timeline, we ran a full-scale sample test on a section of the facility floor. We installed the complete system—prep, prime, coat, and topcoat—using the same products, crew size, and timeline we'd use for the live installation. Then we tested it with wear and pull testing to verify adhesion and durability.

The system passed. That gave Magna confidence we could deliver, and it gave us the data we needed to execute.

The Execution

Each weekend followed the same cadence:

Saturday 6 AM – Saturday 10 PM: Surface prep (grinding, patching, vacuuming), solvent-based epoxy primer application, and 100% solids white epoxy body coat installation. A 4-man crew working a 16-hour shift covered approximately 5,000 sqft per weekend.

Saturday 10 PM – Sunday 8 AM: Cure window. The epoxy cured overnight in a climate-controlled, locked-down environment.

Sunday 8 AM – Sunday 12 PM: Satin urethane topcoat application, then 12+ hours of cure time before the Monday 6 AM production shift.

The polished concrete project ran in parallel on a similar weekend schedule. Once both projects were complete, we installed epoxy safety line striping throughout the facility.

The Result

18,000 total square feet of new flooring installed over four consecutive weekends. Zero production delays. The floor has been in service for months under daily forklift traffic and assembly line operations, and it's holding up exactly as specified.

Fast-turnaround installations work when the execution is proven in advance, the products are selected for the timeline, and the crew knows how to work under pressure. We tested the system before we committed, and we delivered what we promised.

Project Photos