Anti-Slip Floor Preparation During Live Warehouse Operations

Project Type: Anti-slip floor preparation and specialist floor cleaning
Client: Distribution centre
Sector: Warehousing, logistics and fulfilment
Service: Concrete floor deep cleaning and anti-slip coating preparation
Scope: Floor testing review, contaminant removal, deep cleaning and surface preparation
Timescale: One-day visit
Environment: Live distribution centre

Overview of the Project

Exterius was appointed to carry out specialist floor cleaning and preparation within a live distribution centre after areas of concern were identified through the client’s heat-map data.

PTV testing showed that the concrete floor had a low slip rating, indicating a high chance of slips within the affected areas.

Before an anti-slip coating could be applied, the concrete surface required thorough cleaning and preparation.

Exterius carried out a deep clean designed to remove pollutants, contaminants and surface residues that could otherwise prevent the anti-slip coating from bonding correctly.

Following the preparation work, there was a significant increase in floor friction, and the treated areas were left ready for the anti-slip coating to be applied by Exterius’ specialist team.

The Requirement

The client had identified areas of concern within the distribution centre using internal heat-map data.

PTV testing was then used to assess the condition of the concrete floor and identified a low slip rating.

The project therefore required Exterius to prepare the affected areas before the anti-slip coating stage.

The work needed to:

• Remove pollutants and contaminants from the concrete surface
• Prepare the floor so that the anti-slip coating could bond correctly
• Improve floor friction through effective cleaning and preparation
• Be delivered safely within a live warehouse environment
• Adapt around operational conditions on site
• Maintain the required quality standard

The Scope of Work

The project included:

• Working from the areas identified through the client’s heat-map data
• Reviewing the floor areas highlighted through PTV testing
• Deep cleaning the concrete floor
• Removing pollutants and contaminants from the surface
• Preparing the floor for anti-slip coating application
• Using specialist machine-assisted floor-cleaning equipment
• Adapting the work sequence around live warehouse operations
• Leaving the treated areas ready for the anti-slip coating stage

The work was completed during a one-day visit.

The Challenge

The project combined a floor-safety requirement with the practical challenges of working inside an operational distribution centre.

The cleaning stage was critical because contamination left on the concrete could have affected how the anti-slip coating bonded to the floor.

At the same time, the team could not work to a completely fixed sequence.

Night-shift overflow was still clearing from parts of the distribution centre when the team arrived, meaning access to some of the affected areas was delayed.

The team therefore needed to remain flexible while maintaining safe working arrangements and completing the required preparation work.

Key Challenges

1. Preparing a Low-Slip-Rating Concrete Floor

PTV testing had identified a low slip rating within the affected floor areas.

The preparation stage therefore needed to address the pollutants and contamination present on the concrete surface.

Exterius carried out a specialist deep clean to remove these contaminants and prepare the floor for the next stage of the anti-slip treatment.

2. Creating the Correct Surface for Coating

Anti-slip preparation is not simply about making the floor look cleaner.

Surface contamination can prevent a coating from bonding correctly to concrete.

The deep-cleaning process therefore focused on removing pollutants and contaminants from the floor so that the surface was appropriately prepared for the anti-slip coating application.

Following the preparation work, there was a significant increase in floor friction.

3. Working During Live Distribution Operations

The project took place while the distribution centre remained operational.

This meant the team needed to work around the conditions found on site rather than relying solely on the original planned sequence.

Night-shift overflow had to clear before some areas could be accessed.

Exterius adapted the programme accordingly while maintaining safe working arrangements.

4. Delivering the Work Within a One-Day Visit

The cleaning and preparation work was completed during a single-day visit.

This required the team to respond efficiently to changing access conditions while still completing the required floor preparation to the agreed quality standard.

Our Specialist Floor Preparation Approach

Exterius combined information from the client with specialist floor preparation to address the identified areas of concern.

The approach included:

• Using client heat-map information to identify priority areas
• Taking account of the PTV testing results
• Deep cleaning the concrete floor
• Removing surface pollutants and contaminants
• Using specialist machine-assisted floor-cleaning equipment
• Preparing the floor for anti-slip coating
• Adapting the sequence around live operational requirements
• Maintaining safe working arrangements throughout
• Checking that the required quality standard had been achieved

This preparation stage ensured the floor was ready for the subsequent anti-slip coating application.

Working Around Live Operations

Operational flexibility was an important part of the project.

When the team arrived, night-shift overflow meant that some of the planned areas were not immediately available.

Rather than disrupting the live operation, the team adapted the sequence of work and waited for the affected areas to become accessible.

This allowed the project to continue safely while accommodating the distribution centre’s operational requirements.

The Result

The one-day floor-cleaning and preparation project was completed to the required quality standard.

The completed work resulted in:

• Removal of pollutants and contaminants from the concrete floor
• A properly prepared surface for the anti-slip coating
• A significant increase in floor friction following preparation
• Treated areas left ready for coating by Exterius’ specialist team
• Safe delivery around live distribution-centre operations
• Successful adaptation around changing site access
• No reported safety incidents
• No reported communication issues

The project achieved an internal rating of 5/5.

Why Surface Preparation Matters

The effectiveness of an anti-slip flooring system depends on more than the coating itself.

If pollutants, contamination or residues remain on the concrete surface, they can interfere with the coating’s ability to bond correctly.

A specialist preparation process helps ensure that the underlying floor is clean and ready for treatment.

In this project, the combination of:

• Client heat-map information
• PTV testing
• Deep cleaning
• Contaminant removal
• Machine-assisted floor preparation
• Flexible delivery around live operations

Allowed the identified floor areas to be prepared effectively before the coating stage.

The Value of a Testing-Led Approach

Using testing and site data before treatment can help identify where floor-safety concerns are concentrated.

For this distribution centre, heat-map information highlighted the areas requiring attention, while PTV testing provided further evidence of the condition of the floor.

This allowed the preparation work to focus on the areas of concern before the anti-slip coating was applied.

The project demonstrates how floor testing, operational information and specialist preparation can work together to support safer warehouse flooring while allowing live distribution-centre operations to continue.

Testing-led. Safety-focused. Delivered around live warehouse operations.

For anti-slip floor preparation, specialist warehouse floor cleaning or commercial floor-safety solutions, contact Exterius to discuss your requirements.