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Warehouse flooring case study · South Wales

650m² Industrial Line Marking South Wales – Warehouse Case Study

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.

650m² warehouse
Heavy forklift traffic
Vebro EP HBC
Anti-slip finish
Line marking & demarcation
Completed in 4 days
650
M²


Warehouse floor
Heavy forklift truck traffic
EP
HBC


High-build epoxy
Vebro EP Primer and EP HBC
4
DAYS


Four-day installation
Inside a five-day Christmas shutdown
9
MORE


Further repeat work
Nine further jobs commissioned during 2026

The project

Industrial Line Marking South Wales for a Heavy-Traffic Warehouse

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.

  • 650m² warehouse refurbishment
  • Heavy forklift truck and operational traffic
  • Old resin coating worn and delaminating
  • Shot blasting and diamond grinding
  • Minor floor repairs before coating
  • High-build epoxy flooring system
  • Pedestrian routes and safety demarcation
  • Anti-slip finish across the flooring package
Programme requirement:
the warehouse gave SRS a five-day Christmas shutdown window between Boxing Day and New Year. The complete flooring package was delivered in four days so the site could prepare for its scheduled production restart immediately after New Year’s Day.
Factory floor with green pedestrian walkway, grey epoxy coating and yellow line marking
Completed grey high-build epoxy floor with green pedestrian walkway and yellow demarcation

Floor preparation

Removing Worn and Delaminating Resin Before the New Coating

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
.

Close-up of textured high-build epoxy factory floor coating
Close-up of the completed textured industrial epoxy coating

Installed flooring system

Vebro High-Build Industrial Epoxy Coating With PU Seal and Anti-Slip Finish

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

01

Mechanical preparation

Shot blasting and diamond grinding removed worn and delaminating material and created a suitable mechanically prepared base.

02

Repairs and primer

Minor floor defects were repaired before Vebro EP Primer was installed to the prepared substrate.

Vebro Polymers

03

High-build epoxy coating

Vebro EP HBC was installed to create the main RAL 7035 Light Grey industrial floor and RAL 6024 Traffic Green pedestrian areas.

Vebro Polymers

04

PU seal and anti-slip finish

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

Warehouse Line Marking, Pedestrian Routes and Safety 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.

WALK

Green pedestrian walkways

RAL 6024 Traffic Green was used to create clearly defined pedestrian routes through the warehouse.

LINE

Safety-yellow boundaries

Safety-yellow line marking separated pedestrian walkways from adjoining warehouse floor areas.

XING

Pedestrian crossings

White crossing blocks created clearly recognisable points where pedestrian routes crossed operational floor areas.

STOP

STOP floor markings

Large STOP markings were incorporated at agreed locations to reinforce the warehouse traffic-management layout.

RED

Red safety demarcation

RAL 3001 red markings were used for selected hatched and safety-demarcation areas within the completed layout.

ICON

Pedestrian symbols

Pedestrian symbols were applied within the green walkways to make the intended route immediately recognisable.

Heavy warehouse traffic

Industrial Epoxy Flooring for an Area Used by Forklift Trucks

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.

Heavy forklift use

The main grey floor serves an active warehouse environment exposed to repeated forklift truck movement.

High-build epoxy coating

The existing tired resin was replaced with a Vebro high-build epoxy coating system selected for the industrial floor.

Anti-slip finish

The completed flooring package incorporated anti-slip texture across the agreed working and demarcated areas.

Clear pedestrian routes

Green walkways and contrasting markings made the agreed pedestrian route easy to identify against the main floor.

Five-day shutdown

A Christmas Shutdown With No Room for Programme Overrun

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
.

Industrial pedestrian route marked in green with yellow walking symbols beside factory barriers
Completed pedestrian route delivered as part of the four-day Christmas shutdown

Commercial proof

One Warehouse Flooring Project Led to Nine Further Jobs

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.

01

Direct appointment

SRS was appointed directly by the warehouse operator to deliver the flooring package.

02

Programme achieved

The 650m² refurbishment was completed in four days within the client’s five-day shutdown window.

03

Nine further projects

The client has since commissioned SRS for a further nine jobs during 2026.

Completed result

650m² of High-Build Epoxy Flooring, Anti-Slip Protection and Industrial Line Marking

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.

650
M²

Warehouse refurbished

Approximately 650m² of tired industrial flooring was prepared, repaired and recoated.

HBC

Vebro high-build epoxy

The main operational floor was completed using Vebro EP HBC in RAL 7035 Light Grey.

SAFE

Clear demarcation

Green pedestrian routes, yellow lines, white crossings, red markings, symbols and STOP markings formed the safety layout.

4
DAYS

Completed ahead of window

The full flooring package was delivered in four days against a maximum five-day shutdown programme.

Useful warehouse flooring guides

More Advice on Forklift Traffic, Downtime and Existing Resin Floors

These SRS guides cover three of the main issues demonstrated by this South Wales warehouse project.

Related flooring services

Industrial Flooring Services Used on Projects Like This

This warehouse project combined several SRS services into one coordinated refurbishment.

Project FAQs

Industrial Line Marking and Warehouse Flooring Questions

What flooring system was installed on this South Wales warehouse project?

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.

What industrial line marking was installed?

The project included green pedestrian walkways, safety-yellow boundary lines, white pedestrian crossing blocks, pedestrian symbols, STOP markings and selected red safety-demarcation areas.

What colours were used?

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.

Was the warehouse floor designed around forklift traffic?

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.

How was the old resin floor prepared?

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.

How long did the 650m² warehouse refurbishment take?

SRS completed the approximately 650m² flooring package in four days during the Christmas 2025 shutdown. The maximum available flooring window was five days.

What is warehouse floor demarcation?

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.

Did SRS carry out further work for this client?

Yes. Since this Christmas 2025 project, the same client has commissioned SRS for a further nine jobs during 2026.


Planning an industrial floor refurbishment?

Combine Warehouse Flooring, Line Marking and Demarcation in One Planned Installation

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.