
The UK’s leading resin flooring specialist
Step-by-Step Guide to the Resin Flooring Installation Process
Resin is one of the most reliable and long-lasting flooring options available for industrial and commercial spaces. It’s hard-wearing and withstands both tough environments and high footfall. When you’re planning a flooring upgrade or refurbishment, understanding the resin flooring installation process can help you make informed decisions and set realistic expectations around operational disruption and downtime.
Epoxy, polyurethane, and methyl methacrylate (MMA) flooring are ideal for manufacturing, food production, warehousing, and retail environments. However, proper installation is key to achieving the strength, chemical resistance, and seamless finish that make resin flooring such a valuable investment.
The resin flooring installation process involves several stages, and from initial site assessment through to final curing, every step influences the long-term performance of your floor (which could last 10-20 years). This guide takes you through the process step-by-step, so you know what to expect when working with Impact Flooring.
Step 1: Site Assessment and Planning
Every flooring installation project starts with a detailed site assessment. We’ll visit your premises to evaluate the existing substrate (typically concrete) to determine its condition, age, and structural integrity. We’ll also assess environmental factors like moisture or temperature (that would affect the curing process), and examine any existing coatings that may affect adhesion.
Understanding how the space is used helps us recommend the best resin system, whether that’s epoxy for chemical resistance, polyurethane for flexibility, or MMA for fast-track projects. We’ll also map out your facility’s traffic flow and logistics, and highlight any repair work needed ahead of time to ensure a smooth installation process.
Step 2: Surface Preparation
The surface preparation process is critical because it impacts the floor’s long-term performance. The concrete substrate has to be thoroughly cleaned and mechanically prepared to achieve proper adhesion (the resin could fail to bond if the substrate isn’t correctly prepared). This typically involves diamond grinding or shot blasting to remove any existing coatings, debris, contaminants, or laitance – the weak surface layer that forms during concrete curing.
Any substrate cracks or surface defects are filled, levelled, and repaired during this preparation stage to create a smooth, stable foundation for the resin system. We may also apply a damp primer if necessary to prevent future delamination or blistering. That way, the resin bonds as it should, and the new flooring system is set to perform for the long haul.
Step 3: The Resin Application Process
The type of resin we use depends on your site’s specific requirements:
- Epoxy is popular for its strength, durability, and chemical resistance, so it’s ideal for warehouses and industrial sites.
- Polyurethane has superior impact resistance and thermal stability, so it’s often used in food production areas or facilities with temperature fluctuations.
- For ultra-fast turnaround, methyl methacrylate (MMA) can cure in just a couple of hours, allowing installation overnight or during short shutdown windows.
The resin flooring application begins with a primer coat, which penetrates the prepared concrete and creates a strong foundation for subsequent layers. This is followed by one or more body coats, with aggregates added for anti-slip or decorative finishes if required. Finally, a topcoat is applied to seal the surface, delivering a high-performance, seamless floor built to last.
How long does it take to install flooring?
When you’re managing a commercial or industrial facility, every hour of downtime comes at a cost. Take a busy commercial kitchen, for example – prolonged closure for flooring installation simply isn’t feasible. Refurbishing your floors needs to happen quickly to avoid disrupting day-to-day operations, but without compromising on quality. In these scenarios, resin flooring installation is an ideal choice.
Known for its strength and durability, resin flooring is also relatively quick to install. For example, a large, open warehouse could be prepped and coated within two days, ready for light traffic within 12-24 hours and full service within 48-72 hours. A smaller space, like a commercial kitchen, could be completed overnight using a fast-curing resin, ready to resume operations by morning.
Step 4: Resin Drying/Curing Times
Curing timelines for resin floors vary depending on the area size, resin thickness (ranging from 1mm to 10 mm or more), and the application of any specialist coatings or features (such as coved skirting, floor slopes, or drainage). Temperature will also affect the curing rate. Higher temperatures tend to accelerate the curing process, while cooler conditions can extend cure times.
Traditional epoxy and polyurethane floors usually take 24 to 48 hours to cure fully, although they can often handle light foot traffic within 12–18 hours. MMA systems can be fully cured in just a few hours, so there’s a much quicker return to service.
Flexible scheduling to minimise downtime
At Impact Flooring, we know how important it is to keep operations running smoothly and work with your team to develop a schedule that minimises business disruption. Downtime means lost productivity, disrupted workflows, and a potential impact on revenue. That’s why we offer flexible installation, including out-of-hours scheduling, evenings, weekends, and even phased installations if your site can’t accommodate a full shutdown. That way, sections of your facility can remain operational while others undergo flooring work.
Why Choose Impact Flooring for Your Resin Floor Installation?
The key to a successful flooring installation lies in planning, proper surface preparation, and working with experienced professionals who understand your operational requirements. Our team has decades of experience installing floors in the UK’s most demanding environments – from heavy-duty manufacturing and food production to retail and logistics.
We handle every aspect of the project in-house, from planning and prep to application and aftercare, minimising disruption while delivering exceptional results, regardless of the project’s complexity. You can rely on our team to offer expert guidance on the right materials, resin thickness, finishes, and specifications to deliver the best performance and longevity, whether it’s a new-build project or a refurbishment. Get in touch with our team to discuss your project and arrange a site assessment.