To minimise disruption, we completed this warehouse line marking out of hours. Walkway bands were shot-blasted to create a mechanical key, then finished with hand-applied epoxy. We taped every edge for razor-sharp lines and documented the visible difference between shot-blasted profile and polished concrete.
The result: crisp, durable routes that stand up to forklifts and scrubber-dryers—delivered while day-to-day operations carried on uninterrupted.
Project Snapshot & Outcome
Location: UK warehouse (polished concrete). Scope: Out-of-hours programme; shot-blast walkway bands and edges; diamond-grind where needed; prime select areas; epoxy line marking applied by hand; masking/taping for ultra-clean edges. Objective: Long-life walkways and lanes with minimal impact on production.
Outcome: High-contrast, long-wear routes with excellent adhesion and edge definition. The comparison areas clearly show how a shot-blasted profile improves coating bond versus polished concrete.
The Warehouse Manager’s perspective:
You needed durable lines without daytime shutdowns. By moving the programme out of hours and using shot-blasting to key the surface, we delivered epoxy walkways and forklift lanes that last—and we kept your teams productive. Taped edges and careful de-masking gave you the sharp, professional finish that’s easy to enforce and maintain.
The clear result is fewer near-misses, cleaner pedestrian routes, and markings that survive daily cleaning cycles.
Challenges & Solutions
1) Zero daytime downtime
Operations had to continue as normal during the day.
Solution: We executed the works out of hours with short, well-planned phases, reinstating access before the morning shift.
Guidance: HSE: Workplace transport safety
2) Polished concrete & long service life
Polished floors are smooth and can be difficult for coatings to grip—yet the client wanted 5–10 years’ durability.
Solution: We shot-blasted walkway bands and diamond-ground any polished/glazed areas to generate profile, then used a compatible epoxy system with primer where required.
Related reading: Grinding & shot-blasting prep
3) Razor-sharp edges
Walkways needed a premium, straight-edge finish that stays tidy after cleaning.
Solution: We taped out every line, applied epoxy to film thickness, then peeled tape at tack-set for crisp borders that resist fraying and scuffing.
4) Keeping routes intuitive
People and vehicles needed predictable paths during works and after handover.
Solution: Clear temporary diversions and signage during the night works; permanent walkways, keep-clear hatchings at pinch points, and forklift operational areas marked for ongoing discipline.
Best practice: HSG136: Workplace transport safety (PDF)
Technical Specification (What We Used & Why)
Surface Preparation: Targeted shot-blasting to walkway bands and edges for a straight, high-energy key; diamond grinding to remove laitance and polish; dust-controlled vacuum extraction. Where dense or previously sealed, we applied a compatible primer to maximise adhesion.
- Profile: uniform, non-gloss texture to anchor epoxy and reduce underfilm creep.
- Cleanliness: debris removal and degreasing of traffic lanes before coating.
Epoxy Line Marking (hand-applied): High-solids, two-component epoxy selected for abrasion/chemical resistance and scrubber-dryer compatibility.
- Build: typically 1–2 coats to specified film thickness.
- Edges: fully masked; peel at tack-set for sharp borders.
- Options: anti-slip aggregate in doorways/ramps; polyurethane glaze for added cleanability.
Related services:
Warehouse Line Marking ·
Walkways & Pedestrian Routes ·
Indoor Line Removal.
Our Out-of-Hours Process
- Survey & layout: Confirm walkway widths, forklift aisles and keep-clear zones; agree colours and legends.
- Prep windows: Schedule night shifts; set cordons and temporary diversions.
- Mechanical key: Shot-blast bands/edges; diamond-grind polished areas; vacuum and degrease.
- Tape & coat: Mask lines; apply epoxy to film; peel tape at tack-set for crisp edges.
- Cure & reinstate: Verify handling strength; remove cordons; reopen ready for morning operations.
- Sign-off & aftercare: Client walk-through; cleaning/maintenance guidance; optional refresh schedule.
Benefits You Keep Long-Term
Mechanically keyed epoxy lines last longer, look sharper and tolerate cleaning better than paint on polished concrete. Out-of-hours delivery protects throughput, and the finished layout makes routes obvious—reducing hesitation and near-misses.
Net result: a safer, smarter-looking warehouse with fewer call-backs and lower lifetime cost.
Next Steps
Want shot-blasted walkways with razor-sharp epoxy lines—without daytime disruption? We’ll survey, plan an out-of-hours programme and deliver a long-life system built for your traffic and cleaning regime.
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Useful external resources:
HSE: Workplace transport safety ·
HSG136: Workplace transport safety (PDF).
