Resin flooring contractors Leicester manufacturers, food producers and distribution operators call on when a worn floor has to be brought back rather than replaced. Supporting facilities from Meridian and Beaumont Leys to the older textile and production units around Frog Island.
Working for national manufacturers, logistics operators and public sector estates since 1999.
As resin flooring contractors Leicester operators call on for refurbishment work, most of what we are asked to look at is not a new building. The city sits where the M1, M69, A46 and A6 meet, and behind the distribution sheds on those corridors sits a far older estate of textile, food production and engineering premises.
In that stock the problem is rarely throughput. It is age. Slabs have been drilled, patched and re-screeded across several occupiers, the laitance has gone, and the floor dusts continuously into product and equipment.
So the Leicester question is usually how much life is left in the substrate and what it will carry, not which system looks best on a datasheet. Extending floor life without replacing the substrate is what most of this work is actually for.
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 city’s largest employment zones, with logistics, manufacturing and trade units.
Warehousing, manufacturing and distribution premises under heavy forklift traffic.
Established industrial stock with mixed manufacturing and storage activity.
Light industrial, manufacturing and warehousing units on the north-eastern side.
Inner-city industrial and former textile premises north of the city centre.
Commercial and light industrial parks on the M1 Junction 21 and A46 approaches.
Abrasion resistance, joint protection, point-load tolerance and integral demarcation.
Washdown, thermal shock, seamless hygienic detailing, coving and falls to drainage.
Dust control and cleanability around cutting, finishing and packing operations.
Oil, coolant and solvent resistance with impact tolerance around machine bases.
Mixed public and forklift traffic, tyre marking and slip risk at wet entrances.
Vehicle traffic, fuel and salt exposure, and constant water at the wash-down apron.
A patched floor is not a blank substrate. Layers of sealer, repair mortar and contamination left by previous occupiers decide whether anything will bond to it, and none of that is visible from the doorway.
Adhesion depends on what is underneath, so we grind back mechanically and test before proposing a system.
Grinding inside occupied production space runs under H-class extraction with areas screened and waste contained.
Multi-shift sites are zoned and phased so one bay is closed at a time rather than the whole floor.
Most Leicester sites cannot be handed over empty. Warehousing runs to a delivery schedule, food production runs to a shift pattern, and a textile or engineering unit has machinery that cannot simply be moved for a week.
So work is taken overnight, at weekends or bay by bay, with rapid-cure polyaspartic used where the window is genuinely short. We set those out as realistic return-to-service windows rather than promised completion dates, because on a multi-shift site downtime is the dominant cost.
Preparation runs under H-class extraction with areas screened. Respirable crystalline silica is limited under EH40 to 0.1 mg per cubic metre over eight hours, and that matters most in exactly the ageing, occupied buildings where the grinding is heaviest.
A dusting floor is a controllable exposure source, governed by COSHH and the EH40 limit of 0.1 mg per cubic metre.
BS 8204-6 and EN 1504-2 frame what an aged, patched substrate can be asked to carry once it is prepared.
Seamless surfaces, coved skirtings and correct falls, with polyurethane where washdown is routine.
Demarcation of forklift routes and walkways in older buildings where routes were never designed.
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 for the screed. Polyaspartic and MMA sit outside that classification because they describe the resin chemistry rather than the build-up. In Leicester the Type 1 seal and the Type 3 high build coating carry most of the refurbishment work, with polyurethane screed where washdown is routine.
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. On an ageing substrate it is the preparation rather than the resin that usually moves the number.
| 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.
Patch repair, crack filling and making good on multi-layered and previously patched floors.
Walkways, crossings and exclusion zones designed to the space that actually exists.
Damp proof membrane where a substrate fails moisture testing, as a standalone package.
Abrasion resistant floors and joint repairs phased around continuous shed operations.
Hygienic coved systems with falls to drain, installed overnight between services.
Confined workshop floors prepared under extraction with neighbours still trading.
We work across the city regularly, from Meridian, Beaumont Leys and Braunstone Frith through to Hamilton, Frog Island and the inner-city production units. We are Cheshire based rather than Leicester based, so a survey usually happens within days and there is no mobilisation charge for attending.
Usually not. Continuous dusting is normally laitance loss on a worn power-floated slab, and a FeRFA Type 1 seal or a Type 3 high build coating over properly ground concrete will bind it and give a cleanable surface. Replacement is only on the table when the substrate itself has gone.
It means testing before specifying. Older Leicester production floors carry layers of patch repair, sealer and contamination, and adhesion depends on what is underneath rather than on what goes on top. We grind back mechanically and test before proposing anything.
In most cases, yes. Work is taken overnight, at weekends or bay by bay, and rapid-cure polyaspartic returns a floor to use in around two hours where the window is genuinely short. We agree the return-to-service window before anything is ordered.
Not if it is controlled properly. Every machine runs coupled to H-class extraction with areas screened and waste contained. Respirable crystalline silica is limited under EH40 to 0.1 mg per cubic metre over eight hours, which is the standard we work to inside occupied buildings.
From £8 per square metre for a floor seal up to £45 for MMA, inclusive of preparation, labour and materials. Hygienic production floors sit in the middle and rapid-cure systems at the upper end. The full table by system is on the cost page.
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Tell us what the floor does now, what it has already been patched with and how long it can be closed. We attend, test the substrate, and put a written specification and a fixed price in front of you at no cost.
