Facade Cladding Solutions – 220m²
Project Overview
This project covered the refurbishment of a 220 m² industrial floor area. The objective was to return the surface to a sound, clean condition, apply a durable epoxy coating suitable for ongoing heavy use, and introduce clear line marking and hazard zones to support operational safety and traffic management. The work required careful preparation, controlled installation sequencing, and final-stage marking aligned to customer-approved positioning.
This project covered the refurbishment of a 220 m² industrial floor area. The objective was to return the surface to a sound, clean condition, apply a durable epoxy coating suitable for ongoing heavy use, and introduce clear line marking and hazard zones to support operational safety and traffic management. The work required careful preparation, controlled installation sequencing, and final-stage marking aligned to customer-approved positioning.
Specification
Day 1 – Mechanical Preparation and Priming
The full 220 m² area was diamond-ground to remove existing surface laitance, contamination and weak spots, ensuring the concrete substrate was clean, solid and fully keyed. This was followed by the application of WD Primer to achieve optimal adhesion. The primer was selected for its strong wetting capability and compatibility with high-build epoxies in heavier-use environments.
Day 2 – Installation of High-Build Epoxy Coating
Following primer cure, the surface received a full application of Flortex Professional – our heavy-duty, 100 percent solids epoxy resin system designed for industrial floors exposed to frequent movement, load impact and chemical exposure. The product provides a seamless, gloss finish with strong abrasion resistance, making it appropriate for workshop, manufacturing and warehouse environments.
Day 3 – Line Marking and Hazard Definition
Once cured sufficiently for access, the designated line marking was installed using EPS Linemarker, a solvent-free epoxy with high durability and resistance to impact, heat and chemical contact. Red hazard patches were integrated in front of machinery areas, following direct sign-off from the customer to ensure the markings aligned with their operational plan.
The selected coating and marking system ensures that critical zones remain visible under heavy trafficking, allowing for safe movement of staff and equipment.
Day 1 – Mechanical Preparation and Priming
The full 220 m² area was diamond-ground to remove existing surface laitance, contamination and weak spots, ensuring the concrete substrate was clean, solid and fully keyed. This was followed by the application of WD Primer to achieve optimal adhesion. The primer was selected for its strong wetting capability and compatibility with high-build epoxies in heavier-use environments.
Day 2 – Installation of High-Build Epoxy Coating
Following primer cure, the surface received a full application of Flortex Professional – our heavy-duty, 100 percent solids epoxy resin system designed for industrial floors exposed to frequent movement, load impact and chemical exposure. The product provides a seamless, gloss finish with strong abrasion resistance, making it appropriate for workshop, manufacturing and warehouse environments.
Day 3 – Line Marking and Hazard Definition
Once cured sufficiently for access, the designated line marking was installed using EPS Linemarker, a solvent-free epoxy with high durability and resistance to impact, heat and chemical contact. Red hazard patches were integrated in front of machinery areas, following direct sign-off from the customer to ensure the markings aligned with their operational plan.
The selected coating and marking system ensures that critical zones remain visible under heavy trafficking, allowing for safe movement of staff and equipment.
Challenges
- Maintaining strict floor readiness: Achieving a clean, keyed substrate was essential to guarantee adhesion. Any contamination or surface weakness could compromise coating longevity.
- Precision in placement of line marking: Hazard and route demarcation required customer approval and final positioning checks, introducing a dependency that needed coordinating through to final day of works.
- Time-locked sequencing: Preparation, primer cure, full topcoat installation and line marking needed to be completed over consecutive days with minimal downtime, meaning scheduling and material handling had to be tightly planned.
- Durability requirements: The environment called for a finish capable of enduring continuous usage, surface traffic and general operational wear.
- Maintaining strict floor readiness: Achieving a clean, keyed substrate was essential to guarantee adhesion. Any contamination or surface weakness could compromise coating longevity.
- Precision in placement of line marking: Hazard and route demarcation required customer approval and final positioning checks, introducing a dependency that needed coordinating through to final day of works.
- Time-locked sequencing: Preparation, primer cure, full topcoat installation and line marking needed to be completed over consecutive days with minimal downtime, meaning scheduling and material handling had to be tightly planned.
- Durability requirements: The environment called for a finish capable of enduring continuous usage, surface traffic and general operational wear.
Outcome
The floor area was fully refurbished and finished with a seamless, heavy-duty resin coating offering high gloss, strong abrasion resistance and long-term durability. The final surface is straightforward to clean and maintain, and provides a robust platform for machinery zones and traffic. The line marking installation significantly improved workplace safety and operational clarity, defining access routes and controlled-risk zones prior to production use.
All works were delivered within the planned three-day schedule, minimising disruption and restoring the facility to immediate functional use with a professional, clearly designated finish.
The floor area was fully refurbished and finished with a seamless, heavy-duty resin coating offering high gloss, strong abrasion resistance and long-term durability. The final surface is straightforward to clean and maintain, and provides a robust platform for machinery zones and traffic. The line marking installation significantly improved workplace safety and operational clarity, defining access routes and controlled-risk zones prior to production use.
All works were delivered within the planned three-day schedule, minimising disruption and restoring the facility to immediate functional use with a professional, clearly designated finish.
Discuss Your Next Project With Our Team
Speak to our technical team for expert advice on flooring solutions for manufacturing and warehouse environments. Call 01234 846 780 or email uksales@polycote.com.
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