Resin flooring contractors Kirkby manufacturers and trade occupiers rely on for worn industrial concrete brought back into service. Supporting units across Knowsley Industrial Park, Knowsley Business Park, Simonswood and the Acornfield Road and South Boundary Road corridors.
Working for national manufacturers, logistics operators and public sector estates since 1999.
As resin flooring contractors Kirkby occupiers call on regularly, we work almost entirely on what is already there. Kirkby was laid out after the war as a planned industrial town, and Knowsley Industrial Park remains one of the largest estates in the country, running east and north toward the M57 and the A580.
That history sets the problem. A very large stock of mid-sized manufacturing, assembly and trade units dates from the original build, and the presenting fault is almost always a tired power-floated surface that has worn through. Decades of forklift and pallet truck traffic take the surface layer off, and fine dust goes into the working environment, onto product and into machinery.
Underneath sits the other half of the job. These floors carry layers of earlier coatings, screeds and patch repairs, so preparation strategy and adhesion testing decide the outcome far more than the choice of system does.
One of the largest industrial estates in the country, covering manufacturing, storage and trade units.
Modern industrial, distribution and business units adjoining the main industrial park to the south.
Manufacturing, storage and trade units along the northern edge of the town and its approaches.
Established manufacturing and engineering frontage within the older part of the industrial park.
A spine route lined with mid-sized production and warehousing units of varying ages and sizes.
Trade, storage and industrial premises along the main east to west corridor toward the M57.
Dust control, cleanability and machine base impact tolerance with clear line marking.
Mixed public and forklift traffic, wet entrances and a finish that presents well.
Abrasion, joint protection and racking baseplate loads across the industrial park.
Oil, coolant and dropped tool exposure on floors already carrying old repairs.
Fuel and oil resistance with pit edges, jacking points and demarcated test lanes.
Particle control and, where the process needs it, measured electrostatic dissipation.
A dusting floor is usually reported as a housekeeping nuisance. It is a COSHH issue. Worn concrete releases respirable crystalline silica into the space people work in all day, and that is the strongest reason to seal it.
Respirable crystalline silica is limited under EH40 to 0.1 mg per cubic metre over eight hours, making sealing a control measure.
Sixty years of coatings, screeds and patch repairs sit under the surface, so adhesion testing decides what will bond.
BS 8204-6 and the FeRFA range let a seal, a coating and a multi-layer be compared honestly against a fixed budget.
Most Kirkby occupiers run from a single unit with nowhere to move production to. Closing the building is not a phasing preference, it is a cost they cannot absorb, so the work is planned in sections from the outset.
Floors are taken zone by zone, with production, storage, trade counter and workshop areas each handed back before the next is started. A single continuous floor frequently needs different finishes in each of those zones, and that is specified deliberately rather than averaged into one compromise.
Preparation runs under H-class extraction with shared areas screened, which matters more here than almost anywhere. Grinding a dusting floor without containment simply relocates the dust problem the work is meant to solve.
The workplace exposure limit of 0.1 mg per cubic metre over eight hours is the strongest case for sealing.
BS 8204-6 and the FeRFA range compare a seal, a coating and a multi-layer realistically on a worn floor.
Where old coatings and repairs exist, mechanical preparation and adhesion testing determine the outcome.
HSE L24 applies wherever a trade counter, a production area and a forklift route share one building.
FeRFA classifies resin flooring into eight types by build-up and thickness, and BS 8204-6 governs which one a floor actually needs, with EN 13813 covering screeds where levelling is required. Polyaspartic and MMA sit outside that classification because they describe the resin chemistry rather than the build-up. In Kirkby the useful question is which of the lighter types genuinely solves the problem.
FeRFA Type 1. Two or more coats up to 150 microns, binding a dusting substrate and giving a cleanable surface. From £8 per square metre.
FeRFA Type 2. Dual component to 300 microns, solvent free, in gloss, matt or silk. Chemical resistance with a decorative finish.
FeRFA Type 3. Up to 1000 microns over prepared concrete and the system specified on most industrial jobs. Takes colour well for demarcation.
FeRFA Type 4. Multi-coat build at 1 to 3mm with aggregate broadcast between coats, for impact and constant wear.
FeRFA Type 5. Flow-applied at 2 to 3mm for a seamless finish where hygiene and cleaning matter more than impact resistance.
FeRFA Type 7. Three part filled system at 4 to 6mm thickness, giving a self-smoothing finish for heavy and very heavy duty areas.
FeRFA Types 7 and 8. Trowel-applied at 6 to 9mm to take thermal shock, steam cleaning and constant heavy forklift traffic.
Cures at temperatures down to −5°C and is ready in around two hours. Installed overnight or at a weekend it can remove the need to shutdown entirely.
Cures in hours, but the odour can taint food, fabrics and stock and the area must be cleared and ventilated. Better suited to new build and refurbishment projects.
Rates run from £8 per square metre for a floor seal to £45 for MMA, inclusive of preparation, labour and materials. Sealing a dusting floor sits at the bottom of that range, and on most Kirkby units that is genuinely the right answer.
| System | FeRFA | Thickness | Per m² |
|---|---|---|---|
| Floor Seal | Type 1 | Up to 150µm | From £8 |
| Epoxy and PU Coating | Type 2 | 150 – 300µm | £8 – £12 |
| High Build Coating | Type 3 | 300 – 1000µm | £8 – £12 |
| Multi-Layer Flooring | Type 4 | 1 – 3mm | £12 – £16 |
| Self-Smoothing | Type 5 | 2 – 4mm | £20 – £30 |
| Heavy Duty Flowable | Type 7 | 4 – 6mm | £25 – £35 |
| Heavy Duty PU Screed | Type 8 | 6 – 9mm | £30 – £40 |
| Polyaspartic | Chemistry | 300 – 500µm | £38 |
| MMA | Chemistry | 2 – 6mm | £45 |
Inclusive of preparation, labour and materials. Rates assume a sound, accessible substrate and are indicative until the floor has been surveyed. Polyaspartic and MMA sit outside the FeRFA type classification because they describe the resin chemistry rather than the build-up.
A three day shutdown at a plant turning over £2,000 an hour is £120,000 of lost output. On most sites that is several times the price of the floor.
Five contractors quoted one timber processing plant. All five proposed the same system and a three to four day closure. None of them costed the closure.
We proposed a faster-curing system installed across a weekend. A higher rate per square metre, and no shutdown at all. On the client’s own figures the avoided losses exceeded the price of the floor.
We install evenings, weekends and one bay at a time.
Whether a shutdown costs you thousands an hour or simply gets in the way, you do not always have to close your site for a resin flooring installation.
Patch repair, crack filling and joint sealing on original estate concrete and old repairs.
Walkways, forklift routes and zone separation applied in resin rather than in tape.
Damp proof membrane where a substrate fails moisture testing, as a standalone package.
Worn estate concrete ground back and sealed, taking the dust out of the working environment.
Production, storage, counter and workshop areas each finished to suit their own duty.
Oil resistant systems laid over prepared and adhesion-tested concrete, zone by zone.
We work across the town regularly, from Knowsley Industrial Park and Knowsley Business Park through to Simonswood, Acornfield Road and the South Boundary Road units. We are Cheshire based, so a survey usually happens within days and there is no mobilisation charge for attending.
It is a health matter, not housekeeping. Worn concrete releases respirable crystalline silica into the air people breathe all shift, and EH40 sets a workplace exposure limit of 0.1 mg per cubic metre over eight hours. Sealing the floor is a control measure, and it also keeps dust out of product and machinery.
No, but it changes how the job is approached. Estate floors here often carry decades of coatings, screeds and patch repairs, so we grind back mechanically and test adhesion before specifying. What is underneath decides the outcome far more than which system goes on top.
Very often sealing is genuinely enough. BS 8204-6 and the FeRFA range exist so a seal, a high-build coating and a multi-layer can be compared honestly against your budget and your actual duty. We would rather tell you the cheap answer works than sell you a screed you do not need.
Each zone gets what it needs. A trade counter has public footfall and wet entrances, production has machine loads and cleanability, storage has forklift abrasion. They are specified separately across one continuous floor rather than averaged into a single compromise that suits none of them.
From £8 per square metre for a floor seal up to £45 for MMA, inclusive of preparation, labour and materials. Most work here sits at the lower end. The full table by system is on the cost page.
Liverpool · Bootle · St Helens · Skelmersdale · Wigan · Southport · Birkenhead
Tell us how the floor is behaving, what the unit is used for and which zones can be released first. We attend, test the substrate, and put a written specification and a fixed price in front of you at no cost.
