CASE STUDY
How We Sealed 16,000 Sq. Ft. of a Manesar Warehouse Floor
IMT Manesar, Gurugram, Haryana — 2025
How Silicone Crew delivered a complete, professional-grade floor and expansion joint sealing solution for a large warehouse structure at IMT Manesar — working alongside NRM Interior Constructions Pvt. Ltd. on a site that had never been sealed before
| Field | Details |
|---|---|
| Project Type | Industrial Silicone Application |
| Application | New Construction |
| Client | NRM Interior Constructions Pvt. Ltd. |
| Client Industry | Interior Construction & Industrial Fit-Out |
| Site Location | IMT Manesar, Gurugram, Haryana |
| Structure Type | Large-format Warehouse / Industrial Facility |
| Area Covered | 16,000 sq. ft. |
| Surfaces Treated | Floor Joints & Structural Expansion Joints |
| Silicone Product | Wacker WN Weatherseal — Industrial Grade |
| Project Duration | 1 – 2 Weeks |
| Application Team | Silicone Crew Specialist Technicians |
The Background:
A Brand-New Warehouse, Zero Sealing Done
When NRM Interior Constructions Pvt. Ltd. brought Silicone Crew into the IMT Manesar project, the situation was straightforward on the surface — but it carried the kind of risk that becomes very expensive if you get it wrong. The structure was a large warehouse facility located within the IMT Manesar industrial zone in Gurugram, Haryana — one of the most active industrial and logistics corridors in North India. The building was newly constructed. And despite its size and purpose, not a single millimetre of silicone had been applied anywhere on the structure. The floor joints and the expansion joints across the warehouse had been left completely unsealed. Now, in residential construction, an unsealed joint is a nuisance. In an industrial warehouse, it is a structural liability. Forklifts, heavy goods vehicles, pallet trolleys, and daily foot traffic do not forgive an unsealed floor joint. Dust, moisture, and industrial debris enter through the gaps, weaken the slab edges, cause joint deterioration, and over time create uneven surfaces that are both a safety hazard and an asset management problem. Add the seasonal reality of Haryana — monsoon-driven moisture, extreme summer expansion cycles, and winter contraction — and the case for proper sealing becomes urgent.
NRM Interior Constructions needed a specialist who understood industrial silicone application at scale — not a general contractor who would send two workers with a caulking gun. They called Silicone Crew.
The Problem
What Happens When You Don’t Seal a Warehouse Floor
This is the part most people don’t think about until it’s too late. A newly constructed warehouse looks solid, clean, and ready for operations. The slabs are poured, the structure is standing, the cladding is up. But concrete, by its very nature, moves. It expands in heat and contracts in cold. It settles under load. And wherever two concrete slabs meet, or wherever the structural engineer has intentionally introduced an expansion joint to accommodate movement, there is a gap. That gap needs to be sealed correctly, with the right material, applied the right way, before the building goes into operation.
If it is not sealed, here is what happens, and it happens faster than most people expect:
- Moisture enters the joint during the monsoon and capillary action draws it under the slab, accelerating micro-cracking and slab edge degradation over time
- Industrial grime, dust, and chemical residue accumulate in unsealed gaps, making cleaning impossible and creating hygiene and compliance issues in food or pharma-adjacent warehouses
- Heavy vehicle and forklift traffic begins to chip and spall the exposed slab edges along unsealed joints, eventually creating uneven surfaces that damage wheels, pallets, and goods
- The thermal movement of the structure with no flexible sealant in place causes the joint edges themselves to crack and widen, turning a manageable gap into a growing structural problem
- In worst cases, water infiltration under the slab creates voids that compromise the entire floor system and require complete slab section replacement — at a cost many times greater than proper sealing would ever have been
The NRM Interior Constructions site at IMT Manesar was at the starting line of this process. Nothing had failed yet. The question was simple: seal it correctly now, or deal with the consequences in three monsoon seasons. The answer was equally simple.
The Solution
Wacker WN Weatherseal on an Industrial Scale
Silicone Crew’s site assessment team visited IMT Manesar before any work began. This is standard practice — and it is not a formality. The site inspection determines the joint dimensions, the substrate condition, the type of movement expected, and the environmental exposure the sealant will face across its service life. On the basis of that assessment, one product was specified without hesitation:
Wacker WN Weatherseal — an industrial-grade, one-component, neutral-cure silicone sealant engineered for high-movement joints on demanding commercial and industrial structures.
Why Wacker WN Weatherseal for this project? A few reasons that matter in an industrial context:
- Wacker WN Weatherseal is designed to handle significant joint movement
- Wacker WN Weatherseal uses a neutral cure system.
- Wacker WN Weatherseal bonds directly to concrete, mortar, masonry, and metal substrates
- It will not degrade or chalk under the environmental exposure
- WN series is trusted across industrial, commercial, and infrastructure projects globally.
The NRM Interior Constructions site at IMT Manesar was at the starting line of this process. Nothing had failed yet. The question was simple: seal it correctly now, or deal with the consequences in three monsoon seasons. The answer was equally simple.
The Application
How How Silicone Crew Does It Differently
This is where the difference between a Silicone Crew project and a general contractor’s site becomes immediately visible — not in the finished result alone, but in every step that produces it.
01
Site Inspection
Our team carefully evaluates the site to identify:
- Leakage points
- Failed sealant areas
- Cracked joints
- Structural movement gaps
- Water intrusion zones
- Improper previous sealing work
- Exterior facade damage
We assess the building condition, joint width, surface material, exposure to weather conditions, and project requirements before recommending the most suitable silicone sealing solution.
02
Surface Preparation
Proper surface preparation is one of the most important parts of any silicone application project.
Before applying new silicone sealant, we:
- Remove old or damaged sealant
- Clean dust, grease, and contaminants
- Prepare joints for better adhesion
- Apply masking for clean finishing
- Ensure dry and stable application surfaces
At Silicone Crew, we follow proper preparation methods to improve sealant durability and performance.
03
Silicone Application
Once the surface is fully prepared, our trained technicians apply silicone using professional-grade tools and controlled application techniques.
Our silicone application process focuses on:
- Uniform sealant filling
- Smooth finishing
- Proper joint depth
- Strong bonding performance
- Clean visual appearance
- Long-term weather resistance
We use careful hand-finishing methods to create clean and professional silicone lines across windows, ACP panels, glass joints, expansion joints, bathrooms, and facade systems.
04
Finishing & Detailing
At Silicone Crew, finishing quality matters just as much as sealing performance.
After application, we carefully inspect and refine the sealant lines to ensure:
- Smooth appearance
- Consistent joint finishing
- Clean edges
- Proper alignment
- Professional visual quality
We believe silicone work should not only protect the building but also improve its overall appearance.
05
Quality Inspection
Before project completion, our team performs a detailed quality inspection to verify:
- Proper sealant bonding
- Uniform application
- Joint consistency
- Surface cleanliness
- Leakage protection coverage
- Finishing quality
We inspect every critical area carefully to ensure the project meets our workmanship standards.
06
Follow-Up Inspection
At Silicone Crew, our commitment does not end after project completion.
To ensure long-term sealing performance and customer satisfaction, we also encourage a preventive follow-up inspection after approximately 3 months, especially for:
- Exterior facade sealing projects
- High-rise silicone applications
- Heavy rainfall exposure areas
- Leakage repair projects
- ACP joint sealing systems
- Structural glazing work
During the revisit, our team may inspect:
- Sealant stability
- Joint performance
- Adhesion condition
- Weather exposure impact
- Early signs of movement or stress
- Water leakage resistance
This proactive approach helps identify minor issues before they become major leakage or waterproofing problems.
The Scale
16,000 Square Feet Done in One to Two Weeks
Let’s put the scale of this project in perspective. Eight thousand square feet of warehouse floor is not a small residential bathroom. It is a large industrial space with an extensive network of floor joints, expansion joints, perimeter joints, and column base joints running across it. Covering this area with the level of preparation and application quality that Silicone Crew delivered requires a disciplined team, a systematic approach, and the experience to manage quality consistently across a large site over an extended project duration. Silicone Crew’s team completed the full scope of work within one to two weeks. This timeline reflects the right balance between thoroughness and efficiency — fast enough to meet NRM Interior Constructions’ project schedule, careful enough to ensure every joint was prepared, applied, and finished to the required standard. No corners cut to hit the schedule. No schedule extensions because of poor planning. Just professional execution from start to finish. This isn't a marketing line. It's a reflection of the confidence we have in our process, our materials, and our people. When you hire Silicone Crew, you're not just paying for a service — you're investing in a long-term, guaranteed outcome. That peace of mind is included in every quote.
The Scale
Before & After the Work
Before
When Silicone Crew arrived on site, the warehouse floor presented a condition that is unfortunately common across newly constructed industrial structures in India: completely unsealed joints running across the full extent of the floor. Construction debris, dust, and laitance had accumulated in the open gaps. Joint edges were clean but unprotected, with no backer rod, no primer, and no sealant of any kind in place. The floor was structurally sound and newly poured — but entirely vulnerable to the deterioration cycle that begins the moment an industrial facility starts operating.
After
At project completion, every floor joint and expansion joint across the 8,000 square foot warehouse had been sealed with Wacker WN Weatherseal, tooled to a clean concave profile, and finished with straight, sharp edges that reflected the professional standard Silicone Crew applies to every job. The sealant was fully bonded to both joint faces, correctly profiled for movement accommodation, and visually consistent across the entire floor area. The site was clean, the joints were protected, and the warehouse was ready for operations.
Testimony
Client Feedback
NRM Interior Constructions Pvt. Ltd. engaged Silicone Crew for this project based on the recommendation of project contacts who had seen Silicone Crew’s work on previous assignments. The feedback received on completion of the Manesar warehouse project was consistent with what Silicone Crew hears from industrial and commercial clients across its nine-city network: relief at the quality of execution, and recognition that the work was done properly.
"The finish was clean — the lines were straight and it looked very professional. Exactly what we needed on this site."
Key Outcomes
What This Project Demonstrates
The IMT Manesar warehouse project is, in many ways, a textbook example of why professional silicone application matters — and what it looks like when it is done right.
Contact us today for a free site inspection or quick quote
Let's Stop the Leaks For Good.
Whether you're a homeowner with a fungus-ridden bathroom corner or a developer overseeing a 30-storey façade — Silicone Crew is ready. Book a free site inspection and receive a transparent, no-obligation quote within 24 hours.
No commitment required. Free site inspection · Itemised quote within 24 hours · Workmanship warranty on all work
Anil Kumar
Founder, Silicone Crew
Real Words from Real People
Hear from the People Who’ve Worked with Us
The way they explained the problem before even starting gave me confidence. They didn’t hurry, did the job properly, and cleaned up afterward. It’s been months now and everything still looks perfect.
I’ve seen many sealant teams over 20 years, but these people genuinely stand out. They know materials inside out and use them wisely. The results show in both performance and appearance.
Our bathroom edges were constantly leaking despite multiple repairs. The crew visited, explained the issue clearly, and fixed it with total precision. No leaks since then. Rare to find such honest workmanship these days.
We were doing a minimalist interior and needed invisible joints. Silicone Crew’s work blended perfectly with our design. The precision was exactly what we hoped for.
