Overview
A manufacturing facility in London contacted us to quote on their 1,000m² production floor. The existing floor coating was flaking and failing across the main production and storage areas, and new plant installations meant several pedestrian walkways needed repositioning to reflect the updated floor layout. The project demanded a durable resin system with clearly defined traffic separation to meet HSE workplace safety guidelines — and it needed to be completed without disrupting production operations.
Programme Timing — Christmas Shutdown
We carried out this project over the Christmas shutdown period, giving us clear access to the full floor without production machinery in operation. Undertaking the work during a planned shutdown is the most efficient approach for a busy manufacturing facility — the client loses no production time, we have unrestricted access, and the floor is ready when operations resume in January.
Timing a floor installation to coincide with a planned shutdown requires both parties to commit months in advance. The client gets the benefit of zero disruption; we plan our team and material delivery around their calendar. This is a pattern we repeat several times each year — it suits manufacturing clients well and consistently delivers on-programme results.
Surface Preparation
Our team diamond ground the entire 1,000m² floor to remove the failed coating and produce a clean, profiled substrate with a strong mechanical key. All surface defects, cracks, and damaged sections were filled and levelled using epoxy repair mortar to create a smooth, even base ready for the new resin system.
Resin Coating System
We applied a light grey resin floor coating across the main production and storage areas. Once the grey base coat had fully cured, our team returned to mask out the new walkway routes and apply two coats of a red contrast colour to form the repositioned pedestrian walkways.
The walkway positions were agreed in advance with the client's production manager to reflect the new plant layout, ensuring the marked routes were practical from day one rather than overlaid on the old configuration.
Result
The project was completed within the five-day Christmas shutdown window — on time and on budget. The facility now has a fully coated, clearly marked industrial floor with pedestrian walkways that reflect the updated plant layout. The red walkway markings create an unambiguous visual separation between pedestrian routes and forklift and vehicle traffic zones, helping the facility meet HSE requirements for workplace traffic management. The team returned to a clean, professionally finished floor on their first working day of the new year.
Have a Planned Shutdown Coming Up?
We coordinate floor installations around your operational calendar — shutdown periods, weekend windows, or overnight shifts. Tell us your dates and we'll build the programme around them.
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