Warehouse
, UK
Description
This warehouse flooring project involved the full refurbishment of a high-traffic industrial space where the existing concrete substrate had suffered extensive wear due to years of operational use. The client required a long-term solution that would not only address the deteriorating surface but also deliver enhanced chemical resistance and tolerance to point loads from pallet racking and forklift traffic.
Our technical approach included deep mechanical surface preparation to achieve an optimal concrete surface profile (CSP) for bonding, followed by the application of a high-performance epoxy primer designed for substrates prone to moisture vapour transmission. This formed the base for a polyurethane screed system — selected for its resilience to thermal shock, abrasion, and aggressive cleaning agents. The end result is a seamless, slip-resistant floor capable of withstanding the demands of a modern warehouse environment.
Project Scope
- Grinding of the existing concrete slab using a planetary grinder with vacuum extraction, achieving CSP 3–4 for maximum bonding efficiency.
- Filling and patching of cracks, voids, and spalled joints using fast-curing epoxy mortar to restore structural integrity before coating.
- Installation of a low-viscosity, moisture-tolerant, two-component epoxy primer to promote adhesion and seal the porous surface.
- Application of a 6mm trowel-applied polyurethane screed (resin-rich formulation) to provide thermal shock resistance, high compressive strength, and chemical durability.
- Finishing with a pigmented matt polyurethane seal to enhance aesthetics and improve cleanability.
Project Overview
The project was carefully phased to minimise downtime and maintain safety within the operational areas of the warehouse. Initial grinding and preparation ensured all contamination, laitance, and surface defects were removed, while repairs were carried out to preempt substrate movement and wear.
A key technical challenge was managing the high humidity conditions within the space, which was mitigated through the use of a breathable epoxy primer with MVT resistance. The polyurethane screed was applied manually to ensure even distribution and consistent thickness across high-load areas. The completed floor now provides excellent performance under both mechanical stress and chemical exposure, meeting the client’s long-term operational requirements and industry compliance standards.
"Thanks to the Optimum Team for all your hard work on this project, the floor is fantastic"