Case Study · Industrial Epoxy Flooring
Industrial epoxy flooring in the Lake District: 400m² custom light grey resin floor.
A technically demanding factory flooring project in Cumbria — 400m² of bespoke solid colour epoxy resin installed over multiple substrates including bitumen and iron-filled areas, with a custom colour developed on site and delivered on schedule.
400 m²
Floor Area
Industrial
Sector
Lake District, Cumbria
Location
Completed on Schedule
Programme
Bespoke Colour
Finish
Before & After
Industrial epoxy flooring transformation: from contaminated slab to seamless finish.
Drag the handle to compare the original substrate with the finished floor.
The Client Challenge
Factory flooring that needed to be brighter, tougher and seamless.
The client required a durable epoxy resin flooring system capable of withstanding the demands of a heavy industrial environment while creating a brighter, cleaner and more professional workspace. The existing 400 m² slab had been through decades of production use, leaving a patchwork of substrates in very different conditions.
Off-the-shelf grey shades did not match the tone the client wanted, and any light-coloured floor would ruthlessly expose poor preparation. The programme also had to be met without extending the shutdown window.
- Withstand forklift traffic, impact and point loading
- Brighten a dark industrial space and improve light reflectance
- Bond reliably over bitumen, iron-filled and repaired areas
- Match a bespoke light grey shade chosen by the client
- Complete within a fixed shutdown programme
Technical · Multi-Substrate Preparation
Why industrial epoxy flooring demands substrate-specific preparation.
A solid colour industrial floor is only ever as good as the surface beneath it. Rather than applying a single blanket preparation method, each zone was assessed, tested and prepared to its own specification before the resin system was installed.
Bitumen-Contaminated Areas
Bitumen is soft, thermally sensitive and chemically incompatible with standard epoxy primers. These zones were mechanically removed and locally re-profiled so the new system bonded to sound concrete rather than a moving layer.
Why it mattersPriming directly over bitumen risks softening, bleed-through discolouration and eventual delamination.
Iron-Filled / Metal-Impregnated Zones
Areas embedded with iron filings from previous machining activity were diamond ground and shot blasted to expose a clean, open profile, then treated to prevent oxidation staining beneath the coating.
Why it mattersFerrous particles rust under a sealed coating, causing blistering and rust bloom through a light-coloured floor.
Sound Power-Floated Concrete
The main slab was captive shot blasted to CSP 3, with cracks and joints resin-filled and dressed before priming.
Why it mattersA closed power-floated surface offers little mechanical key — profiling is essential for long-term adhesion.
Repaired & Patched Sections
Historic patch repairs of differing age and porosity were individually moisture tested and primed to a tailored specification so absorption rates were equalised.
Why it mattersMixed porosity causes pinholing, uneven gloss and visible patch shadowing in a solid colour floor.
The System
A custom-made solid colour epoxy resin flooring system built for industrial use.
A premium solid colour epoxy resin system was specified for its abrasion resistance, chemical resistance and seamless, joint-free finish. Applied as a fully bonded build over zone-specific primers, it delivers a hard-wearing warehouse floor that cleans easily and reflects light back into the space.
- Premium solid colour epoxy resin, industrial grade
- Seamless and joint-free — no grout lines to harbour dirt
- Forklift, impact and abrasion resistant
- Chemical and oil resistant for production environments
- Anti-slip aggregate options available where required
- High light reflectance for a brighter working environment
Colour Development
A light grey developed specifically for this floor.
No standard shade delivered the tone the client had in mind. Multiple bespoke pigment blends were mixed, applied and fully cured on site so the colour could be judged under the building's own lighting rather than from a colour card.
- 1Reference tones agreed with the client on site
- 2Bespoke pigment blends batched and trialled
- 3Sample panels cured under working light conditions
- 4Final shade signed off before bulk material was batched
- 5Colour-matched across every batch for total consistency
Installation
Step by step, start to handover.
01
Survey & Moisture Testing
Full site survey, relative humidity and moisture readings across every substrate zone before specification was finalised.
02
Multi-Method Preparation
Captive shot blasting, diamond grinding and localised removal of bitumen and iron-filled areas.
03
Repairs & Joint Treatment
Cracks, joints and patch repairs filled with fast-cure resin mortar and re-profiled flush.
04
Zone-Specific Priming
Different primers used across zones to match porosity, contamination risk and moisture readings.
05
Bespoke Colour Development
Multiple pigment trials mixed and cured on site until the client's exact light grey shade was approved.
06
Solid Colour Epoxy Application
Custom-made solid colour light grey epoxy resin flooring system applied at specified build across the full 400 m².
07
Cure, Inspection & Handover
Controlled cure, adhesion and finish inspection, maintenance guidance and on-schedule handover.
Gallery
Project photography.
Before
During
After
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Related Work
More commercial & industrial flooring projects.
Large-Scale Installations
Planning a new warehouse or factory floor?
From single-unit workshops to multi-thousand square metre facilities, we survey, specify and install industrial epoxy flooring and commercial resin flooring systems built around your substrate, traffic and programme.