Built for the way you actually use the space.
Warehouse floors take a beating. Our systems are built for racking loads, MHE traffic and 24/7 operation, with crisp aisle markings and slip-rated zones. Installed in phases so your operation keeps moving.
Heavy-duty flooring systems for high traffic and continuous industrial use.
Warehouse floors take more punishment than most people credit. Racking point loads, VNA truck traffic, pallet drops, changing temperatures, wheel scrub in the pick faces. A floor specified for anything less than the real duty will fail early. Our warehouse builds are designed against the actual operation.
We install warehouse resin flooring across the West Midlands for logistics, 3PL, distribution and manufacturing clients. Every install is designed around the MHE list, racking layout and operational hours, and phased to keep the site trading throughout.
Key benefits
- Rated for counterbalance, reach and VNA truck traffic
- Aisle marking, hatching and pick-face demarcation
- Anti-slip zones for ramps, wet areas and pick faces
- Phased installation to maintain operational uptime
- Dust-free surface — reduces palletised product contamination
- Long service life with straightforward re-coat cycle
Our installation process
Every warehouse flooring project follows the same disciplined sequence. Skipping steps is where floors fail — we don't skip.
- Step 01
Survey and duty specification
We survey the site, review your racking drawings and MHE list (counterbalance / reach / VNA / EPT), and specify a build-up sized for your point loads and traffic pattern.
- Step 02
Preparation
Diamond grinding or captive shot-blasting to the CSP profile the system requires. Existing coatings are removed rather than coated over.
- Step 03
Slab repair
Cracks, spalls, joints and any historic damage are cut out and re-mortared. Movement joints are honoured or bridged based on their function.
- Step 04
Primer and body coat
Penetrating epoxy primer followed by a pigmented body coat — either self-smoothing for pick faces or broadcast for high-abrasion aisles.
- Step 05
Line marking
Full aisle, hatching, pick-face and safety line marking is set out to your layout drawings and coated in a contrasting resin — not painted on afterwards, so it lasts the life of the floor.
- Step 06
Chemical-resistant top coat
A clear or pigmented PU seal locks in the aggregate and delivers the specified slip rating. In heavy-traffic aisles we typically specify an aliphatic PU for maximum abrasion resistance.
- Step 07
Phased handover
We hand each phase back to operations as it cures, with clear signage on the traffic-return times, so warehouse flow is preserved throughout.
Where it works, where it doesn't
We're honest about specification. A system installed in the wrong environment will fail no matter how well it's laid.
Suitable for
- Distribution centres and 3PL operations
- Manufacturing warehouses and stockyards
- Cold and chilled storage (with PU screed)
- E-commerce fulfilment centres
- Racking installations and mezzanine floors
Not suitable for
- External yards without a PU or MMA overlay
- Substrates with rising damp and no DPM (requires remediation)
- Timber decks without a rigid overlay
Advantages and trade-offs
Advantages
- Purpose-designed around your operation
- Line marking that lasts the life of the floor
- Phased installation preserves throughput
- Reduces MHE wear and dust generation
- Long life with a simple re-coat cycle
Trade-offs
- •Areas under coating are offline for 48 hours
- •Full chemical cure takes 5–7 days before heaviest loading
- •Existing badly worn slabs need remedial work first
Durability and lifespan
A properly-specified warehouse floor will typically deliver 15–20 years of service before it needs anything more than a top-coat refresh in the traffic aisles. Racking bays and slower-traffic zones will look nearly as-new at 15 years. The wear pattern is entirely predictable and gives clean planning windows for refresh cycles.
Line marking specified as part of the resin build (rather than painted afterwards) lasts the life of the floor. That eliminates the ongoing cost of re-painting aisle lines every 12–18 months — a hidden operational saving that quickly recovers the up-front cost.
Curing times
Cure schedule at 20°C. Colder conditions extend times; heated cures accelerate them.
| Stage | Time | Notes |
|---|---|---|
| Foot traffic | 12–24 hours | Light walking in socks or clean shoes once the top coat has gelled. |
| Furniture return | 48 hours | Light furniture, tools and shelving can be reintroduced. |
| Vehicle traffic | 5–7 days | Hot tyres and heavier point loads once the PU seal has fully cross-linked. |
| Full chemical cure | 7 days | Chemical resistance, wet cleaning and heavy wear reach design spec. |
Maintenance and aftercare
Warehouse floors want daily sweeping (or ride-on scrubbing) to lift grit before it abrades the top coat. Weekly rotary scrub with a neutral pH detergent keeps the sheen and the slip rating consistent.
Every 5–7 years we recommend a professional inspection and a top-coat refresh in the busiest aisles. This resets the sacrificial wear layer and adds another 5–7 years to the useful life at a fraction of the replacement cost.
Aftercare checklist
- Daily sweep or scrub across all aisles
- Neutral pH detergent only
- Repair any damaged wheels or MHE promptly (metal wheels destroy resin)
- Annual professional inspection
- Traffic-aisle top-coat refresh every 5–7 years
Colour, finish and customisation
Colour zoning is where warehouse resin genuinely pays back — different colours for pick, pack, dispatch and QA zones, contrasting hatched pedestrian walkways, and safety-yellow racking bases. All of it is specified into the build so it lasts the life of the floor.
Where required we can also integrate anti-static coatings, chemical-resistant tanking around bunded areas, and drainage-fall correction as part of the same installation programme.
Available finishes
- ◆Full colour zoning by operational area
- ◆Aisle, hatching and pedestrian walkway marking
- ◆R10–R12 slip ratings by zone
- ◆Anti-static system for electronics DCs
- ◆Bunded and tanked chemical storage zones
- ◆Cold-store rated PU screed
Send us your racking drawings and MHE list — we'll come back with a specification and a phased programme.
Warehouse Flooring — frequently asked
Can you install while we're operating?+
Yes. Almost every warehouse install is phased by aisle or bay so operations run in parallel. We work nights and weekends where the programme requires it.
Will the line marking last?+
Yes. Because the marking is installed inside the resin system rather than painted on top, it lasts the life of the floor. There are no annual re-marking costs.
What MHE can the floor take?+
Standard builds carry counterbalance forklifts and reach trucks. VNA operations, ride-on scrubbers and heavier point loads get thicker builds specified against your actual MHE.
How disruptive is the installation?+
Each phase is offline for 48 hours to foot traffic and 5 to 7 days to heaviest loading. Phased programmes usually mean the wider site stays operational throughout.
How long before we can put racking back?+
48 hours for empty racking, 5 to 7 days for fully loaded racking. We plan the phasing around your rack-out sequence.
Related resin systems
Industrial Flooring
Heavy-duty resin systems built for industrial use.
ReadPU Flooring Systems
Polyurethane systems for the most demanding environments.
ReadCommercial Flooring
Seamless resin floors for offices, retail and hospitality.
ReadAvailable across the West Midlands
We install warehouse flooring across:
Call 07756 971 165 for a free quotation, or email admin@epoxyguys.co.uk.
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