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Mechanical preparation, coating removal and concrete repairs

Industrial Floor Preparation and Repairs

Industrial floor preparation is the foundation of a successful resin flooring project.
Superior Resin Solutions provides diamond grinding, shot blasting, coating removal and
concrete floor repairs for factories, warehouses, workshops and commercial industrial sites.

Book a Free Floor Assessment
Call 07462 436607
Diamond grinding
Shot blasting
Coating removal
Concrete repairs
Industrial floor preparation using a diamond grinder on a concrete factory floor
01
Preparation firstExisting concrete assessed before the resin system is installed
02
Mechanical methodsGrinding and shot blasting selected around the substrate
03
Concrete repairsDamaged areas dealt with as part of the flooring scope
UK
South Wales basedSupporting suitable industrial projects across the wider UK
Start with the existing substrate

Industrial floor preparation starts with the concrete underneath

The finished resin floor is only one part of the flooring system. Before installation,
the existing concrete should be assessed for coatings, contamination, weak surface material,
cracking, damaged areas and previous repairs.

Mechanical concrete floor preparation removes unsuitable material and creates a prepared
surface for the primer and resin system that will follow. It can also expose defects that
were hidden beneath an old coating or previous repair.

Superior Resin Solutions can combine industrial floor preparation, coating removal and
agreed repair work as part of a complete resin flooring refurbishment. This allows the
substrate and the new flooring system to be considered together rather than as separate jobs.

No single preparation method suits every floor:
concrete condition, existing coatings, contamination, floor area, access, required resin
system and the project programme all influence the correct preparation route.
Industrial floor preparation methods

Preparation selected around the existing floor and the system that will follow

The preparation method should be chosen around the substrate rather than forcing every
industrial floor into the same process.

DG

Diamond Grinding

Mechanical diamond grinding can remove laitance, residues, weak surface material and selected existing coatings while preparing the concrete for the next flooring stage.

SB

Shot Blasting

Shot blasting can efficiently prepare suitable industrial concrete floors, particularly across larger open areas where a consistent mechanically prepared surface is required.

CR

Coating Removal

Old resin coatings, weak finishes and unsuitable surface materials may need to be mechanically removed before repairs, primers or replacement flooring systems are installed.

ED

Edges and Detailed Areas

Thresholds, columns, drains, wall edges, machinery bases and restricted areas can require localised preparation alongside the main floor area.

SA

Substrate Assessment

Preparation can reveal cracking, damaged concrete, weak previous repairs and contamination that may need attention before the new resin system is installed.

RR

Ready for Resin Installation

Once preparation, cleaning and agreed repairs are complete, the substrate can move into the specified primer and resin flooring installation.

Preparation in practice

Mechanical preparation and concrete repair work

These preparation visuals show the type of work covered on this page. They are service illustrations rather than photographs of a named SRS project.

Shot blasting industrial concrete floor preparation before resin flooring
Mechanical preparation

Shot Blasting

Mechanical preparation for suitable industrial concrete floors before repair, priming and resin flooring installation.

Industrial concrete floor repair before a new resin flooring system is installed
Concrete repairs

Repair Before Resin Flooring

Damaged areas are prepared and repaired where required before the new resin flooring build-up is installed.

Diamond grinding and shot blasting

Which preparation method is right for the floor?

Both methods are widely used for industrial concrete floor preparation, but neither is
automatically the correct choice for every project.

The condition of the concrete, type and thickness of the existing coating, contamination,
floor area, access, required surface profile and the flooring system that will follow all
influence the preparation method.

  • Identify what is currently bonded to the concrete.
  • Assess weak areas, contamination and previous repairs.
  • Consider how much material needs to be removed.
  • Review edges, thresholds and restricted areas separately.
  • Match the preparation to the resin system that will follow.
  • Allow for cleaning and repair work after preparation.
Industrial Resin Flooring
Industrial Floor Coatings
Diamond grindingUseful for controlled mechanical preparation, coating removal and detailed areas.
Shot blastingEfficient preparation for suitable larger industrial concrete areas.
Local preparationEdges, drains, thresholds, columns and restricted working areas.
After preparationCleaning, inspection and agreed concrete repairs before resin installation.
Industrial floor repairs

Repair damaged concrete before the new resin floor is installed

Industrial concrete can contain local impact damage, indentations, cracks, broken edges,
worn areas and previous repairs. These defects should be considered during preparation
rather than simply covered by the new floor.

01

Indentations

Local damage extending into the concrete can be cleaned, prepared and repaired where it forms part of the flooring scope.

02

Impact Damage

Broken or deteriorated areas in busy industrial zones may require repair before the new resin system is installed.

03

Concrete Cracks

Cracks should be assessed before treatment so the repair approach reflects the condition and any potential movement.

04

Previous Repairs

Old repair areas can require further preparation or removal if they are weak, poorly bonded or unsuitable for the new flooring system.

05

Edges and Thresholds

Doorways, transitions and perimeter areas can contain localised damage that needs detailed preparation and repair.

06

Surface Damage

Weak or worn local areas may only become fully visible once the old coating or surface material has been mechanically removed.

Preparation and repair sequence

How SRS approaches an industrial floor before resin installation

The exact sequence changes with the site, but preparation normally moves from assessment
through mechanical work, repairs and final readiness for the resin flooring system.

01

Assess the Floor

Review the concrete, coatings, contamination, damage, previous repairs, access and proposed flooring system.

02

Mechanically Prepare

Use diamond grinding, shot blasting or other appropriate mechanical methods to prepare the agreed floor area.

03

Clean and Repair

Remove preparation debris, inspect the exposed substrate and complete agreed localised repair work.

04

Proceed to Resin

Once the prepared substrate is ready, installation of the specified primer and resin flooring build-up can begin.

A clear four-stage process

From the existing concrete to a prepared industrial floor

01

Assess

Understand the substrate, site conditions, damage and proposed flooring requirement.

02

Prepare

Mechanically prepare the concrete using the method selected for the project.

03

Repair

Complete agreed local repairs after the substrate has been exposed and cleaned.

04

Install

Move into the specified primer and resin flooring installation when the floor is ready.

Verified SRS preparation case studies

Four real projects showing industrial floor preparation in practice

These verified SRS projects show how mechanical preparation, coating removal,
crack treatment and concrete repairs formed part of complete industrial flooring
refurbishments across warehouses, workshops and food-processing environments.

Completed Rhondda warehouse after extensive industrial floor preparation and repairs
5,000m² Rhondda

Diamond grinding, shot blasting and extensive substrate repairs

The existing warehouse floor contained badly deteriorated old resin,
oil-affected concrete, cracking, holes and damaged areas. SRS used a
combination of diamond grinding and shot blasting across suitable areas,
followed by extensive epoxy repairs and crack treatment before the new
Vebro flooring system was installed.


View the Rhondda case study

Completed Bristol warehouse after diamond grinding shot blasting and concrete repairs
3,500m² Bristol

Two preparation methods with epoxy mortar repairs

SRS combined diamond grinding and shot blasting to remove weak material
and create the required surface profile across the large warehouse.
Indentations and damaged concrete were cleaned out and rebuilt with
epoxy repair mortar before the replacement epoxy flooring system.


View the Bristol case study

Cardiff workshop floor before and after diamond grinding repairs and heavy duty flooring installation
450m² Cardiff

Diamond grinding, crack repairs and joint treatment

The existing workshop concrete was mechanically prepared using diamond
grinding. Minor damaged areas and cracks were chased out and repaired
with epoxy mortar, while existing joints were cut through and treated
before the 9mm Pumadur HF polyurethane floor screed was installed.


View the Cardiff case study

Ebbw Vale food processing floor before and after removal and diamond grinding preparation
120m² Ebbw Vale

Old flooring removal and diamond grinding

The damaged and stained existing floor was removed to expose the concrete
underneath. The substrate was then mechanically prepared using diamond
grinding to create a clean, suitable base before priming and installation
of the 6–9mm Pumadur HF polyurethane floor screed.


View the Ebbw Vale case study

Preparation matched to the floor:
these projects demonstrate that the preparation route changes with the existing
substrate, old coating, contamination, defects and flooring system that will follow.

View All SRS Case Studies
Technical guidance

Preparation should support the complete flooring specification

The substrate, preparation method, resin technology and operational requirements should all be considered together.

HSE Flooring Guidance

Official information covering flooring, contamination, cleaning and wider slip-risk controls.

Read HSE guidance

FeRFA Resin Flooring Guidance

UK resin flooring industry information covering the specification and application of synthetic resin flooring.

Read the FeRFA guide

Discuss the Existing Floor

Send photographs, approximate floor area, current coating, visible damage and the intended flooring requirement.

Request a floor assessment

Related flooring services

Continue from preparation into the correct resin flooring system

Floor preparation and concrete repairs support many industrial resin flooring projects.

Industrial Resin Flooring

Heavy-duty resin flooring for factories, warehouses, workshops and production environments.

View industrial resin flooring

Epoxy Resin Flooring

Epoxy coatings, broadcast systems and seamless flooring for suitable industrial environments.

View epoxy resin flooring

Warehouse Flooring

Resin flooring for logistics, storage, picking, dispatch and forklift areas.

View warehouse flooring

Frequently asked questions

Industrial floor preparation and repair FAQs

Common questions about concrete preparation, coating removal and repairs before resin flooring.

Why does concrete need preparing before resin flooring?

Preparation removes unsuitable surface material and creates a substrate appropriate for the new flooring system. It can also expose damage, weak areas or previous repairs that need attention.

What is diamond grinding?

Diamond grinding is a mechanical concrete preparation method that uses abrasive diamond tooling to prepare or remove material from the floor surface.

What is shot blasting?

Shot blasting is a mechanical preparation method used on suitable industrial concrete floors to create a prepared surface for the next stage of the flooring system.

Is diamond grinding better than shot blasting?

Neither is automatically better. The correct method depends on the substrate, existing coating, contamination, floor area, access and the flooring system that will follow.

Can an old resin floor coating be removed?

Existing coatings can often be mechanically prepared or removed where required. The amount of removal depends on the existing finish and the replacement flooring system.

Can damaged concrete be repaired before resin flooring?

Yes. Localised damage and indentations can be assessed during the preparation stage and repaired where they form part of the agreed flooring scope.

Can concrete cracks be repaired before resin flooring?

Cracks should be assessed first. The treatment depends on the type of crack, surrounding concrete and whether movement or another underlying condition is present.

Do you carry out preparation as part of a complete resin flooring project?

Yes. Floor preparation and agreed repairs can form part of a complete industrial or commercial resin flooring refurbishment.

What should I send for an initial floor assessment?

Send the site postcode, approximate floor area, photographs of the existing floor, visible damage, current coating, site use and available installation programme.

Do you provide industrial floor preparation outside South Wales?

Yes. Superior Resin Solutions is based in Rhigos near Aberdare and supports suitable industrial and commercial flooring projects across South Wales and the wider UK.

Plan the preparation properly

Book an industrial floor preparation assessment

Send the site postcode, approximate floor area, photographs, current coating,
visible damage, contamination and intended resin flooring requirement. SRS will
review the information and explain the most practical next step.


Book a Free Floor Assessment


Send Photos and Project Details

Call SRS
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Superior Resin Solutions UK Ltd provides industrial, commercial and domestic resin flooring across South Wales and the UK. We install durable epoxy, polyurethane, anti-slip, warehouse, factory, food-grade and resin bound systems for businesses, homes and commercial sites.