Traffic Coatings for Warehouse Floors: Which System Works?
Heavy warehouse traffic takes a toll on concrete floors. From forklift tyre marks to oil leaks, pallet drag, and chemical spills, unprotected concrete can deteriorate fast — leading to dusting, cracking, and ongoing maintenance costs. Traffic coatings are applied to concrete surfaces to improve durability, safety, and cleanliness. But choosing the wrong system can mean wasted money and early failure.
This page breaks down the three most widely used warehouse coating types — Epoxy, Polyurethane, and MMA — and compares them based on cure time, durability, slip resistance, chemical resistance, and cost. Whether you're dealing with 24/7 forklift use or occasional pallet jacks, there's a coating system that fits. Scroll down to see how they stack up and how to choose the right one for your space.
Epoxy Coatings
- Cure Time: 24–48 hours (can vary with temperature)
- Durability: Highly abrasion-resistant but more brittle under impact
- Chemical Resistance: Good for oils, solvents, and mild acids
- Slip Options: Can be broadcast with silica or aluminium oxide grit for anti-slip
- Cost: £15–£25 per m² depending on thickness and prep
- Best For: Dry zones with medium forklift traffic, where aesthetics and easy cleaning are a priority
- Considerations: Susceptible to yellowing under UV; moisture in the concrete can cause delamination without proper DPM
Polyurethane Coatings
- Cure Time: 12–24 hours depending on ambient conditions
- Durability: Extremely flexible and impact-resistant; ideal for busy warehouses
- Chemical Resistance: Excellent — handles aggressive cleaning agents and fuel spills
- Slip Options: Can be finished smooth or textured for high-traction zones
- Cost: £20–£30 per m² on average
- Best For: Cold storage, chemical processing zones, areas with thermal cycling or heavy equipment drops
- Considerations: Often needs specialist applicators; fumes during installation can require ventilation
MMA (Methyl Methacrylate)
- Cure Time: 1–2 hours — even in sub-zero environments
- Durability: High — good wear resistance with excellent bond to prepared concrete
- Chemical Resistance: Very high; ideal in labs, food factories, or fuel depots
- Slip Options: Fully customisable with aggregate or broadcast grit
- Cost: £30–£45 per m² due to specialist materials and fast-cure additives
- Best For: Projects with minimal downtime windows, such as 24-hour warehouses or shift-based industries
- Considerations: Strong odour during application; strict substrate prep required or bond may fail
Which Coating Is Right for Your Warehouse?
A Coating May Be Right for You If:
- You operate forklifts or pallet jacks regularly across the same zones
- You want to improve floor hygiene and dust control
- Your facility needs chemical or oil resistance on the floor surface
- You have defined downtime windows and can schedule coating around them
- You want to reduce ongoing maintenance, sealing, and floor cleaning costs
- You need a slip-rated surface for safety near racking or loading zones
A Coating May Not Be Suitable If:
- The slab is moisture-prone and lacks a DPM or vapour barrier
- Traffic types include steel wheels or abrasive scraping actions
- The floor is extremely uneven, flaking, or has multiple hollow spots
- You can’t allow any access restrictions or cure time — not even overnight
- You're only using the space temporarily and want a cheaper short-term solution like paint or sealers
How long do warehouse traffic coatings last?
With proper preparation and application, most traffic coatings last 5–10 years under normal warehouse use. MMA and polyurethane tend to last longer in aggressive environments, while epoxy may need recoating sooner in high-wear zones.
Can coatings be applied to old or damaged concrete?
Yes, but surface preparation is key. Damaged areas should be repaired and the surface mechanically ground or shot-blasted. Moisture levels must be checked, especially for epoxy and polyurethane, which are sensitive to damp slabs.
What’s the fastest system for coating a floor?
MMA is the fastest — it can be applied and fully cured in as little as 2 hours, even at low temperatures. It’s ideal for overnight works or weekend installations with no downtime margin.