Factory Flooring

The UK’s leading resin flooring specialist

Common Factory Flooring Problems and How to Solve Them

A reliable and robust factory floor forms the backbone of any successful industrial operation. In today’s fast-paced and demanding manufacturing landscape, factory flooring must not only support the weight of heavy machinery and equipment but also withstand the wear and tear from constant traffic, exposure to chemicals, and various environmental hazards.

Yet, despite the critical role factory flooring plays in ensuring smooth daily operations, it’s often overlooked and inadequately maintained, leading to costly and time-consuming repairs, reduced productivity, and potential safety risks.

In this post, we’ll delve into some of the most common factory flooring problems that commercial business owners often encounter and provide practical, effective solutions for each. By addressing these challenges head-on, you can maintain a well-functioning, safe, and visually pleasing workspace that meets the ever-evolving demands of your industry.

Cracking and Crazing

Cracks and crazing are prevalent issues that can compromise the integrity and safety of factory floors. They can occur for various reasons, such as improper installation, heavy loads, temperature fluctuations, and the use of inadequate flooring materials. Cracked or crazed floors not only present a significant safety risk to workers but may also cause damage to equipment and result in costly repairs.


The first step in addressing cracks and crazing is conducting regular inspections of the factory floor to detect and rectify any issues before they worsen. For minor problems, epoxy resin-based repair products can fill and seal the cracks effectively.

However, a more comprehensive solution is to invest in a high-quality resin flooring system, such as epoxy or polyurethane-based systems, which are renowned for their durability, strength, and resilience. Resin flooring systems offer superior resistance to cracking and crazing due to their seamless, joint-free installation and excellent load-bearing capacity. Additionally, they can withstand temperature fluctuations, chemical exposure, and heavy traffic, making them an ideal choice for industrial environments.

When considering a resin flooring system, it’s crucial to work with a reputable industrial flooring contractor who can assess the existing damage, recommend the most suitable resin flooring solution, and ensure proper installation. Doing so will help prevent future cracking and crazing issues and provide a long-lasting, low-maintenance factory floor that can endure the daily challenges of a productive workplace.

Uneven or Sloping Floors

Uneven or sloping factory floors can cause significant operational inefficiencies and safety hazards. These issues can stem from improper installation, settling over time, or the use of subpar flooring materials. Machinery and equipment require a level surface for optimal performance, and uneven floors can hinder their functioning. Furthermore, uneven floors increase the risk of trips, falls, and injuries among workers.


Addressing uneven or sloping floors begins with identifying the root cause of the problem. If the issue is localised, self-levelling compounds can be applied to create a level surface.

Resin flooring systems offer excellent self-levelling properties, ensuring a consistently smooth and even surface. Additionally, they can be installed over existing uneven floors to fill in any low spots and create a level surface, eliminating the need to tear up old flooring and reducing installation costs and labour time.

Moisture and Water Damage

Moisture and water damage can have severe consequences for factory flooring, leading to problems such as mould growth, staining, discolouration, delamination, and material degradation.

Sources of moisture can include leaks, condensation, spills, or the use of flooring materials unsuited for high-moisture environments. If left unaddressed, these issues can result in costly repairs and negatively impact the overall efficiency and safety of the facility.


The first step in tackling moisture and water damage issues is identifying the source of the problem and addressing it promptly. For instance, if a leak is the cause, it should be repaired immediately to prevent further damage. In cases of condensation, the facility’s ventilation system should be reviewed and enhanced if needed. Where rising damp is an issue, a damp-proof membrane installed beneath the flooring can help mitigate the problem.

Epoxy and polyurethane-based flooring systems are designed to provide excellent moisture and water damage resistance. These systems form a seamless, impermeable surface that prevents water penetration and protects the substrate from damage. Additionally, these flooring systems are simple to clean and maintain, thus helping to keep moisture levels at a minimum.

Chemical and Abrasion Resistance

Factory floors are frequently exposed to harsh chemicals, solvents, and abrasive materials that can cause erosion, staining, or other types of damage to the floor surface. Over time, this can negatively affect the floor’s appearance, integrity, and functionality, leading to increased maintenance costs and potential safety hazards.


To protect your factory floor from chemical and abrasive damage, it’s crucial to choose a flooring material that offers inherent resistance to these substances. Resin flooring systems are an excellent choice for this purpose. These systems provide outstanding resistance to chemicals, abrasions, and impact, ensuring the floor remains durable and visually appealing even in the most demanding industrial environments.

Resin flooring systems can be customised to offer varying degrees of chemical and abrasion resistance based on the specific requirements of your facility, allowing you to select the most suitable solution that can withstand the unique challenges of your business.

In addition to selecting a suitable flooring material, implementing proper maintenance and cleaning practices is crucial in minimising the impact of chemicals and abrasive substances on the floor. Regular cleaning using appropriate cleaning agents and techniques can help prevent the buildup of harmful substances and prolong the life of your resin flooring system.

Slip Resistance and Safety

Slippery factory floors are a significant safety hazard that can lead to accidents and injuries among workers. Factors such as improper floor maintenance, the wrong type of flooring material, or the use of unsuitable cleaning agents can all contribute to an increased risk of slips and falls.


Ensuring slip resistance and safety starts with selecting a suitable industrial flooring material with built-in slip-resistant properties. Resin flooring systems can be customised with aggregates to increase traction and prevent slips and falls. These systems offer superior slip resistance properties, making them a safe and reliable choice for industrial environments.

In addition to selecting a suitable flooring material, proper maintenance and cleaning practices can also help reduce the risk of slips and falls in your facility. Regular cleaning using low-abrasive cleaning agents is essential for maintaining good traction on the floor surface.

Finally, it’s important to ensure that any spills or standing water are removed immediately, as these can significantly increase the risk of slips and falls.


Factory owners, managers, and maintenance personnel face several challenges when it comes to maintaining their facility’s flooring. Unfortunately, these challenges can negatively impact safety, productivity, and maintenance costs. However, by investing in a high-quality resin flooring system, many of these challenges can be mitigated, resulting in a safe, durable, and visually appealing factory floor.

Resin flooring systems offer several benefits over traditional flooring materials, including superior resistance to cracking, moisture, chemicals, abrasions, and slips. In addition, they are customisable and can be tailored to meet the unique demands of industrial environments, making them a superior choice for factory owners and managers looking for long-lasting, low-maintenance flooring options. 

Contact us today to learn more about our resin flooring solutions and how they can help you address your factory flooring challenges. Our knowledgeable team is readily available to assist you in choosing the perfect flooring solution tailored to your facility’s unique needs and requirements.

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