Warehouse Floor Overlay Solutions (TEST)

Warehouse Floor Overlay Solutions

Industrial Concrete Floor Overlay & Repair Services

At Level Best Concrete Flooring, we specialise in transforming worn, damaged, or uneven industrial floors into high-performance, long-lasting surfaces. Our concrete floor overlay systems provide a cost-effective and sustainable alternative to full slab replacement, trusted by businesses across the UK.

Industrial Concrete Flooring Specialists

As leading industrial concrete contractors, we offer tailored overlay and screed applications to restore and upgrade existing slabs. Whether through a high-performance concrete topping or a precision-applied thin screed, we deliver a smooth, durable finish designed to support the long-term efficiency of your facility. Uneven warehouse floors, poor finishes, and surface deterioration can disrupt operations and create costly downtime. Using advanced solutions such as the FRS floor polishing system or installing a new concrete screed overlay, Level Best ensures your warehouse or industrial flooring performs to the highest standards. Our methods are suitable for both large-scale industrial flooring projects and smaller warehouse refurbishments, adapting to a wide variety of operational requirements.

WHY YOU SHOULD CONSIDER LEVEL BEST

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Proven Warehouse Floor Overlay Solutions

Concrete floor overlays are a widely recognised and proven method in the industrial flooring sector. Endorsed by The Concrete Society and referenced in TR34 4th Edition (section 11.1.4), this approach is an industry-approved solution for enhancing warehouse and industrial floor performance. Overlaying your existing slab not only delivers reliable results but also reduces cost and project timelines compared to full slab replacement. Businesses across logistics, warehousing, and manufacturing sectors rely on overlays to maximise floor durability, safety, and efficiency. Overlay systems also provide clear environmental advantages. By reusing the existing concrete slab as a foundation, embodied carbon emissions are significantly reduced. This sustainable flooring method requires less new concrete and cement, cutting resource use while eliminating the carbon impact of demolition, disposal, and replacement. The result is a green, cost-efficient flooring solution that strengthens your slab, improves performance, and supports your company’s sustainability goals.

Frequently Asked Questions

A concrete overlay is a thin new concrete or cementitious layer applied over an existing concrete slab to restore or enhance its surface. It is used when the existing slab is still structurally sound but has surface damage, unevenness or aesthetics issues. 

An overlay is suitable if the existing slab:

  • Is free from major structural damage or severe delamination
  • Has adequate load-bearing capacity 
  • Can be prepared to provide sufficient bond for the new topping. Overlaying is more cost-effective, faster and more sustainable because it avoids demolition and disposal. 

Overlay thickness depends on the condition of the existing slab, the load demands, and how much level correction is needed. In industrial settings, overlays might range (for example) from a few millimetres up to several tens of millimetres (or more). In certain overlay/topping systems, the thickness also needs to accommodate reinforcement, jointing or carrying traffic loads. 

Proper preparation is critical. Typical steps include:

  • Remove contaminants (oil, grease, coatings, sealants, paint)
  • Repairing loose areas
  • Grinding, shot blasting, or scarifying to create a roughened profile for bonding (achieve correct concrete surface profile)
  • Cleaning and potentially priming 
  • Filling cracks or voids so they do not reflect through the overlay 

If the surface is not well-prepared, the overlay may delaminate, crack or fail prematurely. 

Yes, if cracks are active (i.e still moving) they may reflect through to the overlay. Therefore, crack stabilization, routing or control joints are often addressed before or as part of the overlay design. 

Because warehouses see temperature changes, shrinkage, and dynamic loads (e.g forklifts), the overlay must accommodate movement. Some key points:

  • Overlay joints are generally aligned with joints in existing slab
  • Additional joints may be needed, depending on overlay thickness and stresses 
  • Reinforcement, fibre mesh or dowels may be used to control cracking or assist load transfer 

Curing and drying times depend on the overlay product, thickness, additives, ambient temperature and humidity. In many industrial overlays, a walk-on time might be within 24*48 hours; heavier trafficking may require more time. Level Best will provide you with technical data to follow after installation. 

A properly designed, installed and maintained overlay will give many years of service. Talk to Level Best to find out if this is the right option for you. 

Yes – overlay systems can be designed to accept polishing, dyes, stains or coloured additives. 

Yes — anti-slip aggregates or surface treatments can be integrated or applied to the finished overlay to provide a safer surface, especially in wash-down or wet environments.

  • If the existing slab is in very poor condition (heavily cracked, heaved, spalled), overlaying may not be viable — replacement might be necessary
  • Poor surface prep or contamination leads to delamination or failure
  • Active cracks may reflect
  • If the overlay is too thin for traffic demands, it may wear prematurely
  • Differences in shrinkage or thermal expansion between old and new may cause stresses

On the Level

A word on F.R.S by Sam Wilcox

“For me, it’s all about making smarter, more sustainable choices. I often say F.R.S. is like giving your floor an MOT, it’s a complete service that doesn’t just clean the surface but rejuvenates it, making it ready for whatever you throw at it. We are pleased of how cost-effective it is. Instead of ripping everything out and starting over, we help clients recycle and reuse their existing concrete floor. That’s a massive win when it comes to reducing waste and saving money. What really sets us apart is the efficiency of the service. It’s all-in-one streamlined, hassle-free, no jumping between contractors. We get in, get the job done properly, and leave you with a floor that looks and performs like new. Looking into the eco-friendly side of things, Our blue rinse machine makes a real difference reducing the need for harsh chemicals and cutting down on water waste. I think it’s important that we keep sustainability at the heart of what we do. And we’ve designed the system to be safer and more user-friendly for everyone involved. From our team to our clients, every part of this process to feel smooth, secure, and worth their time. At Level Best, we are committed to delivering flooring solutions that aren’t just good today they’re built to last. F.R.S. reflects everything efficiency, sustainability, and solid results.”

SUITABLE APPLICATION AREAS

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Latest Floor Renovation Projects

Level Best Concrete Flooring Transforms Erith Warehouse Floor Back to Pre-Let Condition

When the previous tenant’s lease expired on a warehouse unit in Erith, near Charing Cross, the landlord was left with a heavily worn and dilapidated concrete floor. Recognising the need for a specialist approach, they turned to Level Best Concrete … Read More

Floor Renovation project completes in Heywood, Greater Manchester

Level Best Concrete Flooring, based in Goole, has successfully completed a major floor renovation project in Heywood, Greater Manchester, restoring a dilapidated warehouse floor back to prime condition for its new tenant. When the previous tenant’s lease expired, the 5,000 … Read More

Floor Renovation Project in Lutterworth, Leicestershire

Level Best Concrete Flooring have completed a major 100,000 square foot dilapidation, refurbishment and repair project on Magna Park in Lutterworth, Leicestershire, East Midlands. Level Best were engaged to return this warehouse floor in Lutterworth, East Midlands back to its … Read More

Concrete removal, recycle and replace

When an existing client came to us and asked for a new external concrete hardstanding for his busy haulage yard he was pleasantly surprised to learn that at Level Best Concrete Flooring we have the skills and knowledge to carry … Read More

Kind words from our Clients

Level Best Concrete Flooring has carried out numerous different types of concrete flooring contracts on behalf of Stainforth Construction. Level Best has always achieved a quality end product within the timescales agreed and we will be continuing to use them in the future.
Stainforth Construction
Senior Quantity Surveyor

Contact Us

Level Best Concrete Flooring Contractors, Innovation House, Swinefleet Common, Swinefleet, Goole, DN14 8DW 01405 819199 enquiries@levelbestconcreteflooring.co.uk Mon-Fri 8am - 5pm

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