Concrete warehouse floors are exposed to constant abrasion from forklifts, pallet trucks, and foot traffic. Without the right coating, surface dusting, staining, and wear can develop quickly, especially in turning zones and loading points. A properly applied traffic-grade coating helps protect the slab while improving safety, hygiene, and visibility. This guide explains how to apply a traffic coating to warehouse floors using commercial-grade primers, resins, and application methods.
Traffic coatings must bond to clean, open concrete. Start by shot blasting or diamond grinding to achieve a surface profile of CSP-2 or CSP-3. Remove all dust, laitance, oils, and surface sealers. For old coatings or polish, use heavier grinding to expose sound concrete underneath. Vacuum the surface thoroughly after prep. Poor prep is the main cause of coating failure in warehouses.
Use a solvent-free or low-viscosity epoxy primer to seal the surface and improve adhesion. Apply with a roller or squeegee and work quickly to avoid dry patches. Let the primer cure as per the data sheet, typically 12 to 24 hours. In porous or damaged areas, a second coat may be required. Make sure the primer is fully dry before applying any build coats.
Traffic coatings are usually high-build epoxy or polyurethane systems, applied at 300 to 500 microns dry film thickness. Mix the resin and hardener exactly as directed and apply using a notched squeegee followed by back-rolling. Work in controlled zones and maintain a wet edge to avoid roller marks. Keep foot traffic off the slab until the first coat has cured.
In wet zones, loading docks, or where forklifts brake frequently, add anti-slip media. Broadcast silica, aluminium oxide, or polymer grit into the wet base coat. Use full rejection if maximum grip is needed. Once cured, vacuum or sweep the loose particles before sealing with a topcoat. For dry, indoor zones, a smooth finish may be acceptable depending on traffic and safety protocols.
Apply the second coat once the base layer has cured. This coat seals in the aggregate and builds film thickness for durability. Use a clean roller and apply evenly to avoid gloss variation or patchy finish. Colour and sheen consistency improve with this final layer. Allow full cure before allowing forklift traffic. This typically takes 3 to 7 days depending on resin type and ambient temperature.
Use line marking paint or coloured resin to define walkways, forklift lanes, hazard borders, or storage zones. This improves safety and organisation within the warehouse. Always apply line markings after the traffic coating has cured and been cleaned. Use masking tape for crisp edges and allow the markings to dry fully before reopening the floor to foot or vehicle traffic.
Traffic coatings should be inspected every 6 to 12 months for signs of wear, especially in turn zones or loading points. Clean regularly with non-abrasive scrubbers and avoid harsh degreasers that can strip the topcoat. Recoat worn areas before full breakdown occurs to maintain performance and prevent dusting. With proper upkeep, traffic coatings can last 5 to 10 years in heavy-use environments.
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