Client Overview:
One of DC Flooring’s long-standing clients, with whom we regularly deliver specialist industrial flooring solutions, including resin flooring systems and polished concrete finishes. Having built a strong working relationship over numerous successful projects, our client once again entrusted our team to restore an existing warehouse floor to a consistent, high-quality finish.
The warehouse contained multiple flooring systems installed over time, resulting in an inconsistent appearance and varying surface conditions. The client’s objective was to create a seamless, uniform finish across the warehouse while ensuring the existing concrete slab was preserved and prepared for a new high-gloss coating.
Challenge:
As with many refurbishment projects, the true extent of the floor condition only became apparent once work had commenced.
The project involved the take up and removal of approximately 1,500m² of existing screed. Initially believed to be between 5–7mm thickness, investigations revealed that in some areas the screed had been built up to an unexpected depth of 30mm.
Removing such a substantial layer of screed presented a significant challenge. The underlying warehouse slab was scheduled to receive a glossy resin finish, meaning that any damage, breakout or excessive planer marks would remain visible in the completed floor.
Further complications arose as work progressed. The team discovered the original concrete slab had previously been heavily planed before the levelling screed had been installed. This significantly increased the complexity of the removal process, requiring exceptional care to avoid further damaging an already compromised concrete surface.
In addition to the screed removal, DC Flooring also carried out extensive repairs, including the preparation of redundant VNA guidance chases, concrete slab repairs and comprehensive joint restoration to create a sound foundation for the Resdev Pumatech system.
Solution:
Rather than rushing the preparation process, DC Flooring adopted a methodical approach, continuously assessing the condition of the slab while carefully removing each layer of screed.
Specialist planning equipment and experienced operators ensured material was removed gradually, protecting the integrity of the structural slab beneath. This level of precision was essential to minimise further damage and provide a surface suitable for the final decorative coating.
To ensure consistency across the warehouse, on-site sample areas were produced throughout the project. These allowed the client to approve the proposed finish while enabling the team to refine the repair techniques and colour match the refurbished areas with the existing warehouse floor.
By combining extensive concrete repairs, joint restoration and careful preparation, the team successfully transformed a heavily worn and inconsistent floor into a uniform substrate ready for resin finish.
Outcome:
Despite the unforeseen challenges encountered during the screed removal, the project was completed to an exceptionally high standard.
The repaired and refurbished areas blended seamlessly with the existing warehouse floor, delivering the consistent appearance the client had originally requested. The extensive preparation work ensured the new flooring system could be installed without visible imperfections caused by damaged concrete or excessive planer marks.
The project demonstrated the importance of experienced floor preparation, technical problem-solving and attention to detail when working on refurbishment projects where unknown site conditions can significantly impact the scope of work.
Conclusion:
Industrial flooring refurbishment projects rarely go exactly as planned, particularly when working with existing concrete slabs and historical flooring systems.
This project highlighted flexible project management and an experienced installation team capable of adapting to unforeseen challenges without compromising quality.
Although additional work was required during the screed removal process, DC Flooring successfully delivered a uniform, high-quality warehouse floor that met the client’s expectations and maintained the professional standard expected across their facility.
For businesses looking to refurbish existing warehouse floors, this project demonstrates how specialist preparation, concrete repair expertise and careful planning can overcome even the most challenging site conditions to deliver outstanding results.
Need to Restore or Refurbish an Existing Warehouse Floor?
Whether your facility requires concrete floor preparation, resin flooring, polished concrete, joint repairs or warehouse floor refurbishment, DC Flooring has the experience and specialist equipment to deliver exceptional results.
Speak to our flooring specialists today to arrange a free site survey and quotation.
