Resin flooring contractors Dudley forges, foundries and fabrication shops rely on for floors rated by thickness rather than by adjective. Supporting metal trades and engineering premises from Pensnett Trading Estate and Peartree Lane to Wallows, Brierley Hill and the Stourbridge Road corridor.
Working for national manufacturers, logistics operators and public sector estates since 1999.
As resin flooring contractors Dudley operators call on regularly, we specify against conditions a logistics floor never meets. The borough carries the region’s densest surviving concentration of metal trades, served by the A461, the A4123 Birmingham New Road and the A491, and threaded by the Dudley and Stourbridge canals.
Hot metal, dropped billets and castings, scale, swarf, quench water and cutting fluids all arrive on concrete that was frequently laid decades ago on made ground.
Where a distribution shed wears gradually along a forklift line, a forge bay floor fails locally, violently and repeatedly in the same few places. Throughput has nothing to do with it.
Almost every failed industrial floor comes back to the same four variables: the condition of the substrate, the quality of the preparation, the temperature and contamination on site, and whether the system was matched to the traffic it actually carries.
Get those right and a resin floor runs for fifteen years and more. Get them wrong and it blisters, delaminates or dusts within a year or two, regardless of what the manufacturer’s datasheet claims.
We survey the substrate before we quote it. That means moisture testing, an assessment of what is already down, and a written specification naming the system, its FeRFA type and its thickness — so you know what you are buying and so does anyone who has to approve it.
Diamond grinding or shot blasting back to sound concrete, moisture testing to confirm the substrate is dry enough to coat, and repair of cracks, joints and spalled areas before any resin is mixed. Skipping this is why cheap floors blister and peel.
Substrate condition, preparation quality, temperature and contamination are the four variables that determine whether a resin floor lasts fifteen years or fifteen months. FeRFA guidance is explicit: resin flooring follows the substrate profile beneath it.
One of the largest managed industrial estates in the country, dominated by metals and fabrication.
Established manufacturing, engineering and trade units sitting close to the A461 in Dudley.
Mixed fabrication, storage and trade premises on the Brierley Hill side of the borough.
Industrial and commercial units on a former heavy industry site over at Halesowen.
A near-continuous frontage of industrial, trade and storage units along the A491 corridor.
Older process and workshop buildings on the Dudley and Stourbridge canal network.
Thermal cycling, radiant heat and hot debris needing heavy-duty polyurethane screeds.
Impact from stock handling with abrasion from sand and scale across the working bays.
Spark and spatter resistance, dropped-stock impact and cutting fluid exposure.
Coolant and oil resistance with concentrated point loading under machine bases.
Extreme abrasion and dust ingress across preparation and surface treatment areas.
Heavy stock movement with wet entrance slip risk at roller-shutter thresholds.
A coating specified for a warehouse will fail within months in a forge. What survives radiant heat, dropped billets and scale is build-up depth and aggregate content, not a hardness figure printed on a datasheet.
System depth in millimetres and aggregate content decide survival under dropped stock, not hardness claims.
BS 8204-6, EN 13813 and the FeRFA Type 8 heavy-duty screed classification are the honest framework here.
Oil-soaked floors, previous patching and moisture from made ground make preparation the decisive work.
These estates are made up of many independent workshops rather than a few large sheds, so projects are smaller-grained and planned around single-shift working rather than national distribution schedules.
Work is taken bay by bay or over a weekend, with detailing formed up to machine bases and fixed plant rather than stopping short of them. Demarcation has to work around what is bolted down.
Preparation runs under H-class extraction with areas screened. Grinding a laitance-shedding works floor releases respirable crystalline silica, limited under EH40 to 0.1 mg per cubic metre over eight hours, and in a small unit there is nowhere for it to go.
BS 8204-6, EN 13813 and FeRFA Type 8 heavy-duty polyurethane screeds for hot-process bays.
Thickness and aggregate content stated in millimetres rather than described as hard wearing.
The EH40 limit of 0.1 mg per cubic metre over eight hours supports sealing a dusting works floor.
EN 1504-2 protection with moisture testing, the commonest cause of delamination in older stock.
FeRFA classifies resin flooring into eight types by build-up and thickness, and BS 8204-6 governs which one a floor actually needs, with EN 13813 covering the screed material itself. Polyaspartic and MMA sit outside that classification because they describe the resin chemistry rather than the build-up. In Dudley the heavy-duty screeds lead, because heat and impact decide the specification.
FeRFA Type 1. Two or more coats up to 150 microns, binding a dusting substrate and giving a cleanable surface. From £8 per square metre.
FeRFA Type 2. Dual component to 300 microns, solvent free, in gloss, matt or silk. Chemical resistance with a decorative finish.
FeRFA Type 3. Up to 1000 microns over prepared concrete and the system specified on most industrial jobs. Takes colour well for demarcation.
FeRFA Type 4. Multi-coat build at 1 to 3mm with aggregate broadcast between coats, for impact and constant wear.
FeRFA Type 5. Flow-applied at 2 to 3mm for a seamless finish where hygiene and cleaning matter more than impact resistance.
FeRFA Type 7. Three part filled system at 4 to 6mm thickness, giving a self-smoothing finish for heavy and very heavy duty areas.
FeRFA Types 7 and 8. Trowel-applied at 6 to 9mm to take thermal shock, steam cleaning and constant heavy forklift traffic.
Cures at temperatures down to −5°C and is ready in around two hours. Installed overnight or at a weekend it can remove the need to shutdown entirely.
Cures in hours, but the odour can taint food, fabrics and stock and the area must be cleared and ventilated. Better suited to new build and refurbishment projects.
Rates run from £8 per square metre for a floor seal to £45 for MMA, inclusive of preparation, labour and materials. Hot-process and impact bays sit at the upper end, because thickness is exactly what is being paid for.
| System | FeRFA | Thickness | Per m² |
|---|---|---|---|
| Floor Seal | Type 1 | Up to 150µm | From £8 |
| Epoxy and PU Coating | Type 2 | 150 – 300µm | £8 – £12 |
| High Build Coating | Type 3 | 300 – 1000µm | £8 – £12 |
| Multi-Layer Flooring | Type 4 | 1 – 3mm | £12 – £16 |
| Self-Smoothing | Type 5 | 2 – 4mm | £20 – £30 |
| Heavy Duty Flowable | Type 7 | 4 – 6mm | £25 – £35 |
| Heavy Duty PU Screed | Type 8 | 6 – 9mm | £30 – £40 |
| Polyaspartic | Chemistry | 300 – 500µm | £38 |
| MMA | Chemistry | 2 – 6mm | £45 |
Inclusive of preparation, labour and materials. Rates assume a sound, accessible substrate and are indicative until the floor has been surveyed. Polyaspartic and MMA sit outside the FeRFA type classification because they describe the resin chemistry rather than the build-up.
A three day shutdown at a plant turning over £2,000 an hour is £120,000 of lost output. On most sites that is several times the price of the floor.
Five contractors quoted one timber processing plant. All five proposed the same system and a three to four day closure. None of them costed the closure.
We proposed a faster-curing system installed across a weekend. A higher rate per square metre, and no shutdown at all. On the client’s own figures the avoided losses exceeded the price of the floor.
We install evenings, weekends and one bay at a time.
Whether a shutdown costs you thousands an hour or simply gets in the way, you do not always have to close your site for a resin flooring installation.
Making good cratering, crack stitching and rebuilding around machine bases and plinths.
Walkways and traffic routes designed around fixed plant and applied in resin, not paint.
Damp proof membrane where a substrate fails moisture testing, as a standalone package.
Heavy-duty screeds at full depth where radiant heat and hot debris defeat a coating.
Impact tolerant systems laid around fixed plant inside single-shift working windows.
Oil-soaked concrete decontaminated, moisture tested and prepared under extraction.
We work across the borough regularly, from Pensnett Trading Estate at Kingswinford and Peartree Lane through to Wallows at Brierley Hill, Coombswood at Halesowen and the Stourbridge Road corridor. We are Cheshire based, so a survey usually happens within days and there is no mobilisation charge for attending.
Because radiant heat and thermal cycling debond it and hot debris burns through it. What survives is build-up depth, which is why BS 8204-6, EN 13813 and the FeRFA Type 8 heavy-duty polyurethane screed classification exist. A system specified for a warehouse will usually fail within months here.
Thickness and aggregate content, not surface hardness. A dropped billet or casting is a single high-energy event, and a thin brittle system fractures and exposes the concrete. We state the build-up in millimetres so you can see what you are getting rather than relying on a durability adjective.
Usually, but only after the contamination is dealt with. Oil ingress and moisture from made ground are the two commonest causes of delamination in this borough, so we establish both at survey, grind out what needs removing and price the preparation separately.
No, but it shapes the method. Work is taken bay by bay or over a weekend around single-shift working, with detailing formed up to machine bases rather than stopping short of them, and demarcation designed around what is bolted down.
From £8 per square metre for a floor seal up to £45 for MMA, inclusive of preparation, labour and materials. Heavy-duty screeds for hot and impact bays sit at the upper end, with preparation priced separately. The full table by system is on the cost page.
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Tell us how hot the bay gets, what lands on the floor and how old the building is. We attend, test the substrate, and put a written specification and a fixed price in front of you at no cost.
