The UK’s leading resin flooring specialist
The Cost of Factory Flooring Installation and Its Long-Term Benefits
When you’re running a factory, flooring probably isn’t the first thing on your mind. Your factory flooring is a crucial piece of infrastructure that directly impacts safety, productivity, and your bottom line, though, and a high-quality industrial flooring solution pays off over time, especially in demanding environments. From heavy machinery to harsh chemicals, you need a solid surface that can withstand the serious wear and tear of your daily operations.
But how much does factory floor installation really cost, and what kind of return can you expect over time? Whether you’re upgrading an existing surface or planning a new build, there are key factors that influence flooring costs – and some long-term savings and benefits to consider.
What Influences the Cost of Factory Flooring?
No two factories are alike, which is why installation costs can vary considerably. Understanding what drives those costs can help you make an informed decision, budget effectively for the project, and avoid unnecessary expenses down the line. Here is a list of every cost factor that will influence your overall budget:
- Your choice of flooring material
- The size of the facility
- The condition of the existing substrate
- Accessibility (difficult-to-access areas may require more time and effort)
- The need for drainage or sloped surfaces
- Health and safety requirements (like anti-slip finishes)
- Colour and branding preferences
- Finishes and coatings for chemical resistance.
Let’s explore these flooring costs in more detail…
Material selection
Your choice of material is one of the most significant cost drivers. Epoxy resin and polyurethane systems are two of the most popular options for industrial flooring, and for good reason. Epoxy flooring is cost-effective, highly durable, and suitable for heavy-duty environments. Polyurethane offers excellent resistance to thermal shock and chemicals, making it ideal for certain industries like food processing or textile manufacturing. While painted concrete or vinyl options might seem cheaper (at first), they often lack the resilience required for demanding industrial settings. The need for ongoing maintenance and frequent replacement can cost more in the long run.
Flooring thickness and durability
Factory environments place high stress on floors. Thicker screeds offer increased strength and impact resistance, essential for areas exposed to forklifts, pallet trucks, and constant foot traffic. A thin floor coating might cost less upfront, but would wear out quickly in a busy environment, unable to stand up to the rigours of a factory environment. While a thicker floor means more material (which affects the initial outlay), it also results in better durability and a longer lifespan. We help clients choose the right thickness of factory flooring based on expected usage, wear, and traffic intensity.
Installation time and complexity
Complex layouts, multiple rooms, or specific design features (like safety line demarcations and stencilling) can extend installation times and labour costs. The same applies to floors that need levelling or floor preparation (like shot blasting or diamond grinding), or factories with specific requirements like creating slopes for drainage or specific finishes for hygiene or safety. At Impact Flooring, our team is trained to work efficiently within tight timeframes, often scheduling factory floor installations around production hours to avoid disrupting your operations. Working out of hours or splitting work into phases, while avoiding downtime, may increase labour requirements, but it saves you money by keeping your factory running.
Factory size and layout
It goes without saying: the larger the space, the higher the cost. Larger areas will require more flooring material. But it’s not just square footage that matters – awkward layouts, machinery that can’t be moved, or areas requiring specialist preparation (e.g., cleaning, grinding, repairing cracks) can add to the cost. That said, large-scale installations often benefit from economies of scale. Once we’re on-site, we’re equipped to work quickly across large areas with minimal disruption.
The Long-Term Payoff of Quality Factory Flooring
It’s easy to fixate on upfront costs, but factory flooring should be seen as a long-term investment – focusing solely on the cheapest option can be a false economy. A well-planned and professionally installed flooring system delivers a host of long-term benefits that far outweigh the initial investment.
Long-term durability = lower lifetime costs
Quality resin flooring can withstand years of abuse from forklifts, dropped pallets, foot traffic, and chemical exposure without cracking, flaking, chipping, or wearing out. That means:
- Fewer repairs
- Less downtime for emergency fixes
- Lower maintenance and fewer repairs
- No need to replace your factory flooring every few years.
The superior strength and longevity of epoxy and polyurethane resin mean you’ll avoid the hidden costs of budget flooring solutions. These surfaces can withstand years of industrial traffic, chemical exposure, and daily cleaning without breaking down. Less maintenance over the floor’s lifespan saves you time and money in the long run.
Improve workplace safety
A damaged or poorly maintained floor is a health and safety risk, particularly in factories where spills, oils, or debris are common. Anti-slip finishes, demarcated walkways, and chemical-resistant surfaces can all contribute to a safer workplace by eliminating trip hazards and reducing the risk of accidents and injuries. Resin floors can be finished with slip-resistant coatings, colour-coded walkways, and hazard zones to reduce accidents and keep people moving efficiently. And when your staff feel safe and confident in their environment, employee morale and productivity tend to improve too.
Easy to maintain
Concrete is often the default choice for factory floors, but on its own, it’s rarely the ideal long-term solution because it’s naturally porous, which means it absorbs liquids like oil, solvents, and corrosive chemicals. This can lead to staining, contamination, and even structural weakening over time, causing cracks, crumbling, or pitting. Repairing cracked concrete (resurfacing, cleaning, patching, or replacing sections) is time-consuming and costly, and often only a temporary fix.
Investing in a durable flooring system from the outset (such as an epoxy resin floor) significantly reduces these recurring expenses because it’s fit for purpose. Epoxy resin floors are seamless and non-porous, so dirt and spills sit on the surface rather than seeping in. That makes them easy to clean and maintain, helping you meet hygiene standards without extra effort or specialised equipment. This kind of low-maintenance surface makes life significantly easier for your team.
How Impact Flooring Helps You Save on Factory Flooring
We understand that factory downtime is costly. That’s why we plan each project around your operational schedule, often installing flooring overnight or in stages. Whether you’re running a chemical plant, engineering works, or a manufacturing line, covering 200m² or 2,000m², our team will design and install durable flooring that fits your needs, budget, and timelines.
Why choose Impact Flooring?
We pride ourselves on:
- Decades of industrial experience
- High-quality industrial flooring solutions tailored to the specific needs of factories
- Expertise in epoxy and polyurethane resin systems, known for their strength and durability
- Minimal disruption with flexible scheduling
- Custom finishes, safety features, and clear demarcation
- A professional team that values quality, safety, and speed
- Cost-effective solutions that deliver significant long-term value.
We don’t just lay floors; we install reliable, long-term solutions for demanding industrial environments. Contact us to speak with our expert team about your factory floor.
FAQs
What is the cost of installing factory flooring?
It varies depending on materials, facility size, and the complexity of the job. For an accurate quote, we would need to assess your site and provide a quote.
What are the most durable materials for factory flooring?
Epoxy resin industrial flooring is renowned for its excellent durability and resistance to the high impact of heavy loads, chemicals, and abrasion in manufacturing environments.
How long does factory flooring last?
With proper installation and care, high-quality resin floors can last 10–20 years or more in industrial settings, offering a significant return on investment.
Can factory flooring be installed during off-hours to minimise downtime?
Absolutely. At Impact Flooring, we regularly install flooring during off-hours or weekends to keep your operations running smoothly.