Mechanical preparation
Shot blasting and diamond grinding removed worn and delaminating material and created a suitable mechanically prepared base.
Warehouse flooring case study · South Wales
Superior Resin Solutions refurbished a 650m² South Wales warehouse floor during the Christmas 2025 shutdown, combining Vebro high-build epoxy flooring, anti-slip protection, pedestrian walkways and detailed industrial line marking and floor demarcation for a site exposed to heavy forklift truck traffic.
The project
SRS was appointed directly by the warehouse operator to refurbish approximately 650m² of industrial flooring during its Christmas 2025 shutdown.
The existing resin floor was old and tired, with areas of wear and delamination. The warehouse also experiences heavy forklift truck traffic, meaning the new flooring package needed to address both the condition of the substrate and the day-to-day operational demands placed on the finished surface.
The project went beyond recoating the main floor. It also incorporated a coordinated system of industrial line marking, pedestrian walkways, crossings, STOP markings, coloured safety zones and floor demarcation to make routes and working areas easier to identify.

Floor preparation
A high-build epoxy coating is only as reliable as the surface beneath it. The existing warehouse floor had areas of worn and delaminating resin that could not simply be covered with another coating.
SRS used a combination of shot blasting and diamond grinding to remove unsuitable material and mechanically prepare the floor. Minor defects were repaired before the new Vebro system was installed.
Using more than one preparation method allowed the team to deal with the different floor areas and details encountered across the warehouse rather than relying on a single process throughout.
Read more about
industrial floor preparation and repairs
.

Installed flooring system
The flooring specification combined mechanical preparation, repairs, Vebro EP Primer, Vebro EP HBC high-build epoxy and a PU UV WB Seal with anti-slip finish.
Vebro describes EP HBC as a pigmented, solvent-free high-build epoxy coating designed to protect concrete substrates.
View Vebro EP HBC product information
Shot blasting and diamond grinding removed worn and delaminating material and created a suitable mechanically prepared base.
Minor floor defects were repaired before Vebro EP Primer was installed to the prepared substrate.
Vebro Polymers
Vebro EP HBC was installed to create the main RAL 7035 Light Grey industrial floor and RAL 6024 Traffic Green pedestrian areas.
Vebro Polymers
The flooring package incorporated Vebro PU UV WB Seal together with the specified anti-slip finish before the final demarcation details were completed.
Vebro Polymers
Industrial floor demarcation
The finished floor used colour, symbols and marked crossing points to distinguish pedestrian movement from the main warehouse floor and support the client’s agreed traffic-management layout.
RAL 6024 Traffic Green was used to create clearly defined pedestrian routes through the warehouse.
Safety-yellow line marking separated pedestrian walkways from adjoining warehouse floor areas.
White crossing blocks created clearly recognisable points where pedestrian routes crossed operational floor areas.
Large STOP markings were incorporated at agreed locations to reinforce the warehouse traffic-management layout.
RAL 3001 red markings were used for selected hatched and safety-demarcation areas within the completed layout.
Pedestrian symbols were applied within the green walkways to make the intended route immediately recognisable.


Heavy warehouse traffic
The warehouse is exposed to heavy forklift truck traffic, so preparation, coating selection, anti-slip texture and the visibility of pedestrian routes all formed part of the wider flooring package.
The main grey floor serves an active warehouse environment exposed to repeated forklift truck movement.
The existing tired resin was replaced with a Vebro high-build epoxy coating system selected for the industrial floor.
The completed flooring package incorporated anti-slip texture across the agreed working and demarcated areas.
Green walkways and contrasting markings made the agreed pedestrian route easy to identify against the main floor.
Five-day shutdown
The work took place during the warehouse’s Christmas shutdown between Boxing Day and New Year’s Day 2025.
SRS had a maximum five-day window to complete the floor because production was scheduled to restart immediately after New Year’s Day.
Within that window the team had to mechanically prepare the existing resin, complete local repairs, install the primer and high-build epoxy coating, form the coloured pedestrian zones, complete the industrial line marking and apply the final protective and anti-slip components.
The full 650m² package was completed in four days, leaving the flooring programme finished within the shutdown period.
For sites where downtime drives the flooring specification, see our
warehouse resin flooring and downtime guide
.

Commercial proof
The strongest proof of the client’s satisfaction is the work that followed. Since completion of this Christmas 2025 warehouse project, the same client has commissioned SRS for a further nine jobs during 2026.
SRS was appointed directly by the warehouse operator to deliver the flooring package.
The 650m² refurbishment was completed in four days within the client’s five-day shutdown window.
The client has since commissioned SRS for a further nine jobs during 2026.
Completed result
The finished warehouse combines a light-grey operational floor with contrasting pedestrian routes, safety markings, crossings and demarcated areas built around the way the site is used.
Approximately 650m² of tired industrial flooring was prepared, repaired and recoated.
The main operational floor was completed using Vebro EP HBC in RAL 7035 Light Grey.
Green pedestrian routes, yellow lines, white crossings, red markings, symbols and STOP markings formed the safety layout.
The full flooring package was delivered in four days against a maximum five-day shutdown programme.


Useful warehouse flooring guides
These SRS guides cover three of the main issues demonstrated by this South Wales warehouse project.
What to consider when flooring is exposed to repeated forklift movement, turning and operational wear.
How preparation, system selection, curing and site access influence warehouse flooring programmes.
Common reasons resin floors break down, including preparation, contamination, substrate condition and system selection.
Related flooring services
This warehouse project combined several SRS services into one coordinated refurbishment.
Pedestrian routes, crossings, forklift zones, work areas, safety symbols and floor demarcation.
High-build epoxy and resin coating systems for industrial concrete floors and refurbishment projects.
Warehouse resin flooring for forklift routes, storage facilities, loading areas and high-traffic operations.
Resin systems for production, storage, logistics and operational industrial environments.
Textured resin finishes selected around traffic, contamination, wet use and cleaning requirements.
Epoxy flooring and coating systems for warehouses, factories and commercial working environments.
Shot blasting, diamond grinding and repairs before new resin systems are installed.
Resin flooring for operational factories, workshops, engineering areas and production environments.
Project FAQs
The mechanically prepared and repaired floor received Vebro EP Primer followed by Vebro EP HBC high-build epoxy coating. The project also incorporated Vebro PU UV WB Seal and the specified anti-slip finish.
The project included green pedestrian walkways, safety-yellow boundary lines, white pedestrian crossing blocks, pedestrian symbols, STOP markings and selected red safety-demarcation areas.
The main operational floor was RAL 7035 Light Grey. Pedestrian routes were RAL 6024 Traffic Green, safety boundaries were yellow and selected red markings were RAL 3001.
Yes. The warehouse experiences heavy forklift truck traffic, which was one of the important operational considerations when planning the preparation, industrial epoxy coating, anti-slip finish and floor layout.
The old resin was worn and delaminating in areas. SRS used shot blasting and diamond grinding to mechanically prepare the substrate before completing minor repairs and installing the new Vebro flooring system.
SRS completed the approximately 650m² flooring package in four days during the Christmas 2025 shutdown. The maximum available flooring window was five days.
Floor demarcation uses contrasting colours, lines, crossings, symbols and marked zones to make agreed pedestrian routes, traffic routes, work areas and restricted spaces easier to identify. It forms part of the client’s wider traffic-management and site-safety arrangements.
Yes. Since this Christmas 2025 project, the same client has commissioned SRS for a further nine jobs during 2026.
Planning an industrial floor refurbishment?
Send SRS the site location, approximate area, photographs of the existing floor, traffic levels, required markings and available shutdown window. We can review the existing surface and help plan the preparation, resin flooring and line-marking package.
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.