From 2,000m² to 10,000m²: How We Handle Large-Scale Industrial Flooring Projects

Discover our proven approach to large-scale industrial flooring projects, from initial survey through to handover. Specialist techniques for floors up to 10,000m² and beyond.

The Challenge of Large-Scale Industrial Flooring

Installing epoxy resin flooring across thousands of square metres presents unique challenges that small-scale projects simply don't encounter. Maintaining consistent thickness, achieving uniform colour, managing cure times across vast areas, and coordinating with ongoing operations all require specialist expertise and equipment.

At Evo Resin Flooring, large-scale industrial installations are our speciality. We've refined our processes through countless projects in warehouses, distribution centres, manufacturing plants, and logistics facilities across the UK.

Our Large-Scale Capabilities

Phase 1: Detailed Site Survey and Planning

Every large project begins with a comprehensive site survey. Our team assesses substrate condition, identifies problem areas like oil contamination or moisture issues, and maps out the installation sequence. We factor in your operational requirements, access points, and any existing equipment that cannot be moved.

Planning for industrial flooring installations involves coordinating materials delivery, crew scheduling, and equipment logistics. For a 5,000m² warehouse floor, we might use 15-20 tonnes of resin materials – all of which needs to be on site, properly stored, and accessible when needed.

Phase 2: Surface Preparation at Scale

Surface preparation is critical for adhesion and longevity. On large-scale projects, we deploy ride-on diamond grinders that can process 1,000m² per day compared to 100m² with walk-behind machines. Shot blasters are used for heavily contaminated areas or where aggressive profiling is required.

Phase 3: Systematic Application

Applying resin across thousands of square metres requires careful coordination. We work in defined bays, maintaining wet edges while managing cure times. Multiple applicators work in sequence, with dedicated mixing stations keeping material flowing continuously.

For factory flooring with heavy-duty requirements, we typically apply systems of 4-6mm thickness, sometimes incorporating quartz aggregates for additional durability and slip resistance.

Project Timeline by Size

Minimising Operational Disruption

We understand that closing a logistics facility or distribution centre for weeks isn't always possible. Our phased installation approach allows sections of your floor to be completed and handed back while work continues in other areas.

For logistics flooring projects where downtime equals lost revenue, we frequently work nights and weekends. Our teams are experienced in 24-hour operations when schedules demand it.

Quality Assurance at Scale