Overview
Our team delivered a full industrial resin flooring system across 3,400m² of warehouse floor in London. The project ran over several weeks and involved extensive site preparation, large-scale defect repair, 45 tonnes of Industrial Top cementitious screed, a water-based epoxy sealer system, and a final topcoat in SF41 BS00A05. The floor was handed over clean, level, and ready for immediate service — transformed from a contaminated, debris-heavy substrate into a light-grey industrial surface capable of sustaining forklift and pallet truck traffic for years.
Initial Site Clearance
Before any flooring works began, we cleared a full skip of dust and construction debris from the building floor. This was done deliberately to allow other trades on site to continue their work safely while our preparation phase was held back. Large defective areas of the existing slab were brought up to a workable level using concrete infills ahead of the main preparation programme.
Surface Preparation
Once the building was clear of other trade activity, our flooring team returned to carry out full mechanical preparation across the entire floor:
- PCD (polycrystalline diamond) grinding and full vacuum across all 3,400m²
- Bobcat planer deployed to reduce high spots across the slab
- SBR primer applied in two coats to ensure full bond between substrate and screed
- Deep defects infilled with Industrial Top to level the surface ahead of screeding
- All existing joints marked and protected before screed installation commenced
Industrial Top Screed Installation
45 tonnes of Industrial Top cementitious screed was installed across the prepared substrate, creating a hard-wearing, level base ready for the coating system. Industrial Top is a heavy-duty overlay designed specifically for large industrial floors that must carry forklift traffic, resist contamination, and maintain a dust-free, smooth surface over years of operational use.
After curing, our team carried out a full STR rub-down and vacuum to remove laitance and any surface contamination before the sealer was applied.
The Bobcat planer was essential on this project — several areas of the slab had high spots that would have consumed excessive screed material to level by compound alone. Mechanically reducing those high spots first saved both material and time across a floor of this scale.
Epoxy Sealer and Topcoat System
A water-based epoxy sealer coat was applied across the full 3,400m² floor. Once cured, our team filled all pin holes and cut new expansion joints to match the existing slab layout — a necessary step to prevent future cracking from natural building movement.
The floor was then given a final STR sand and vacuum before the SF41 topcoat was applied in BS00A05, a neutral light grey finish that maximises light reflectance inside the warehouse and provides a clean, uniform appearance across the full floor area. Sikaflex expansion joint sealant was applied on completion to finish the installation.
Result
A 3,400m² warehouse floor taken from a debris-covered, heavily defected slab to a clean, level, professionally finished industrial surface — delivered on programme. The client received a floor ready for immediate operational use, with clearly defined expansion joints to protect long-term performance, and a light-grey finish that works for both the building's function and its presentation to visiting clients and logistics partners.
Have a Large Warehouse Floor That Needs Attention?
We assess, specify, and deliver industrial resin floors across London and the South East — on programme, with a written guarantee on every project.
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