Existing Warehouse (Birmingham) 2021m2 of Resin Floor Dilapidation's

What the client wanted to achieve

Working for a very experienced contractor that specialises in dilapidation and works for a vast number a landlords this project was similar to one we had previously carried out were a very poor standard of an epoxy coating had been installed with fatefully little or no mechanical surface preparation, as the landlord had already paid out for a large area (2021m2) to be installed and put back to its original condition the spotlights were on Contact Flooring Group to get this right, the first thing that we spotted was not only no preparation had taken place but no repairs had been carried out which not only stood out but also proved the previous installer was not up to the job, here is what we did.

The solution 

After various meetings on site between Contact Flooring Group, the contractor and the client we agreed that the original coating not only had to be removed but following that additional careful mechanical preparation was essential to not only totally remove the existing coating but also to totally expose the existing concrete substrate as a number of essential resin repairs were probably the most important part of the project.

Once the preparation had taken place using various mechanical methods we then set about the repairs and leveling a number of undulations in the substrate, this was carried out using various resin repair mortars and mixed resin systems, once these had cured overnight and sanded down by using an STR grit pad sanding machine we installed a squeegee applied solvent free epoxy resin coating to the total area, this was thicker than normal to help further fill the imperfections.

Once this squeegee applied epoxy resin coating had cured overnight it was time to install the final finished coating, similar to the first coating but this time by roller another epoxy based solvent free high build coating was installed which not only provided a great looking surface but also a hard wearing fit for purpose finish, a small walkway was also installed which enhanced the area which will not only please the new tenants but will also give many years of good service, the most important part of this project was the clients comment to the contractor which came back as simply “Outstanding” 

Common questions

Why do epoxy warehouse floor coatings fail?

Poor surface preparation is a common cause. On this 2,021m² Birmingham warehouse, the previous epoxy coating had been applied with little or no mechanical preparation of the concrete and no repairs beforehand, so it did not perform. Mechanically preparing the slab first is what allows a resin coating to bond properly to the concrete underneath.

Can a resin floor be recoated over an old, failing coating?

Not when the existing coating has been poorly applied. In this case it was agreed on site with the dilapidations contractor and the client that the old coating would be removed completely and the concrete mechanically prepared before any new resin went down. Coating over a failing layer risks the new floor failing with it.

What does a resin floor dilapidations job involve?

It involves bringing a warehouse floor back to an acceptable standard for the landlord. Here that meant removing the failed coating, mechanically preparing the concrete, making resin repairs to level uneven areas, sanding, applying a solvent-free squeegee epoxy coat to fill imperfections, then rolling on a solvent-free high-build epoxy topcoat. A small walkway was also installed.

Why use a squeegee-applied epoxy coat before the topcoat?

A thicker, solvent-free squeegee epoxy coat fills the remaining imperfections in the concrete after repairs and sanding. That gives a more even base, so the solvent-free high-build epoxy topcoat that follows can be rolled on to give a durable, good-looking surface. On this Birmingham dilapidations project the client described the finished result as outstanding.