Right arrow Hazardous Material Storage (HAZMAT) Flooring

Flooring Solutions for
Hazardous Material Storage (HAZMAT) Facilities

Q: What kind of flooring is suitable for HAZMAT storage areas?

HAZMAT storage facilities typically use a reinforced concrete slab as the base, with surface finishes selected to suit the hazardous substances on site. Bunded zones, flammable stores and decanting points often receive chemical-resistant resurfacing, while marshalling and access corridors may use polished concrete to create smooth, easy-to-inspect surfaces that support containment and emergency plans.

Q: Can flooring works be carried out while hazardous materials remain on site?

In many cases flooring upgrades can proceed while hazardous materials remain on site, as long as they are carefully planned. The store is divided into phases, areas are cleared and isolated in turn, and temporary barriers and revised traffic routes are agreed. This allows the facility to keep operating while individual compounds and aisles are refurbished in a controlled way.

Q: How do you ensure the floor supports spill containment requirements?

Spill containment is addressed through both the slab and the surface system. Bund walls, kerbs, falls and drainage are reviewed and repaired where necessary, and protective resurfacing can be used to form a continuous lining. The goal is to keep liquids within designated zones and to channel them towards collection points so that spill procedures can be carried out effectively.

Q: Do you provide static-dissipative flooring for flammable stores?

Where flammable atmospheres are present, conductive or static-dissipative flooring can be incorporated into the design. These systems are normally installed as part of a specialist resurfacing build-up over the concrete base and are selected to align with the site’s hazardous area classification and earthing arrangements.

Q: Can you refurbish older HAZMAT floors that have multiple layers of failed coating?

Yes. Older HAZMAT stores often have several layers of coatings and patch repairs. These can be removed back to a sound substrate, with damaged concrete rebuilt where required, before a new flooring specification is applied. This results in a single, consistent system that is easier to inspect, maintain and demonstrate within safety and compliance documentation.

Q: How long can I expect a refurbished HAZMAT floor to last?

The life of a refurbished HAZMAT floor depends on the types of chemicals present, vehicle movements and cleaning practices. When the slab and surface system are properly specified and maintained, the floor can remain in service for many years. Routine inspections and prompt attention to localised damage help extend that service life and avoid more intrusive repairs later on.

Warehouse Flooring Solutions delivers engineered concrete slabs, polished concrete floors and specialist resurfacing systems for HAZMAT stores across the UK. Floors are configured to support segregated storage, spill response and safe movement of drums, IBCs and packaged hazardous goods.

20 +

Years
Experience in HAZMAT Storage Flooring

Hazardous material stores must manage chemical compatibility, fire load, vapour control and emergency access while still working as practical warehouses. We install and upgrade floors that integrate with bunded areas, hazardous zones, fire compartments and safety systems, helping you demonstrate control to regulators, insurers and customers.

Our Expertise

Flooring Needs in HAZMAT Storage Facilities

HAZMAT stores combine pallet racking for packaged goods, drum and IBC compounds, gas cylinder cages, flammable stores and sometimes small process areas. The floor has to cope with a mix of vehicle routes, spill risk and hazardous area requirements. Surfaces must support containment, allow rapid clean-up and remain compatible with a range of chemicals, extinguishing agents and cleaning products.

Many operators use protective resurfacing systems over heavy-duty concrete slabs in bunded zones, with falls arranged towards channels or sumps. In marshalling, staging and link corridors, polished concrete flooring is often adopted for its smooth, low dust finish, similar to the approach taken in chemical storage warehouses and logistics hubs.

Requirement for floors that help contain leaks and direct spills towards designated collection points.
Compatibility with acids, alkalis, solvents, fuels and other hazardous substances stored on site.
Need to accommodate forklift routes, pedestrian walkways and emergency corridors with clear markings.
Ability to integrate with kerbs, ramps, bund walls and thresholds without creating trip points.
Options for static control and earthing in areas classified for flammable atmospheres.

Flooring Problems in HAZMAT Storage Areas

When floors in hazardous material stores start to fail, the issues quickly move from minor nuisance to potential compliance concern. Local defects can undermine containment, complicate emergency response and make it harder to demonstrate effective control during inspections.

Cracks in bunded areas or around kerbs that may allow liquids to escape the containment zone

Softened or etched surfaces caused by repeated contact with specific chemicals

Movement at slab joints under racking uprights or cylinder pallets leading to rocking and impact

Low spots where water, foam or spilled product collects instead of draining towards sumps

Smooth or polished areas becoming slippery when contaminated with oils or fuels

Old coatings lifting, exposing bare concrete and making visual inspection more difficult

Right arrow Our Process

How We Upgrade Floors in HAZMAT Storage Facilities

STEP 1

Assessment and
Hazard Review

We start by walking the store with your HSE and operations teams, reviewing the substances held, bund layouts, hazardous area classifications and known weaknesses in the existing floor. We log areas of damage, ponding, joint issues and historic spill locations, as well as any current improvement actions from audits or insurer surveys.

Double arrows STEP 2

Floor Design,
Containment and Marking

We develop a design that may include new concrete slab construction in loading and tanker areas, chemical-resistant resurfacing solutions within bunds and flammable stores, and polished concrete zones for marshalling and picking aisles. Falls, joint treatments, kerbs and line marking are planned together so that containment, segregation and emergency routes are all supported by the flooring layout.

Double arrows STEP 3

Installation,
Commissioning and Handover

Works are phased so that key compounds remain in service wherever possible. Temporary barriers, clear signage and agreed vehicle routes separate work areas from live storage. Defective floor sections, bunds and thresholds are rebuilt as required before resurfacing is applied. The finished floor is then handed back ready for your leak testing, hazardous area checks and emergency drill updates prior to full restocking.

BS 8204

Floors are installed and finished in line with BS 8204, supporting predictable movement of forklifts and pallet trucks, and providing the surface regularity required around bund walls, kerbs and racking lines.

BS EN 206

Concrete works follow BS EN 206 guidance for mix, cover and curing, giving a robust base for HAZMAT storage that can carry racking loads, vehicle movements and specialist resurfacing build-ups.

CSCS Certified

Our operatives hold CSCS cards and work within permit systems, controlled access routes and strict site rules common within hazardous material stores and major industrial facilities.

SMAS Worksafe

SMAS Worksafe accreditation confirms compliance with SSIP schemes, supporting structured safety management on flooring projects in HAZMAT facilities and wider manufacturing sites.

Right arrow FAQ

HAZMAT Storage Flooring
Common Questions

What kind of flooring is suitable for HAZMAT storage areas?

Flooring for HAZMAT stores is usually based on a reinforced concrete slab with surface systems selected to suit the substances present. Bunded zones, flammable stores and decanting points often receive chemical-resistant resurfacing that stands up to spills and cleaning agents, while marshalling zones and access corridors may use polished concrete finishes to provide a smooth, easy-to-inspect surface. The aim is a floor that works with your containment, segregation and emergency plans rather than against them.

Can flooring works be carried out while hazardous materials remain on site?

Yes, provided works are planned carefully and risk controls are agreed in advance. We typically divide the store into manageable sections and agree which areas can be cleared and isolated at each stage. Temporary barriers, signage and revised traffic plans keep vehicles and pedestrians away from the work zone, and materials are selected and handled in line with your site safety rules. Many clients continue operating throughout the project, with only localised reductions in capacity while specific compounds are refurbished.

How do you ensure the floor supports spill containment requirements?

Containment starts with the base structure and the detailing at its edges. During design we review bund wall heights, joints, thresholds and falls, then propose repairs or alterations where performance is compromised. Damaged concrete around kerbs and bunds is removed and rebuilt, and protective resurfacing systems can be installed to create continuous linings. The finished layout is intended to help keep liquids within defined zones and to move them towards collection points where they can be safely recovered.

Do you provide static-dissipative flooring for flammable stores?

Where flammable liquids, gases or powders are handled, it is often necessary to control static build-up. We can incorporate conductive or static-dissipative flooring within the overall design, usually as part of a specialist resurfacing build-up over the slab. These solutions are selected in line with your hazardous area classification and can be extended into associated production or filling areas, similar to the approach used in certain manufacturing plants.

Can you refurbish older HAZMAT floors that have multiple layers of failed coating?

Many established sites have accumulated several generations of coatings, patch repairs and local modifications. We can remove loose and incompatible material, mechanically prepare the concrete beneath and rebuild damaged sections before installing a new system. This approach helps restore a single, coherent flooring specification that is easier to inspect, maintain and document within your safety management system and COMAH or DSEAR records where relevant.

How long can I expect a refurbished HAZMAT floor to last?

Service life depends on the chemicals handled, the intensity of vehicle movements and the cleaning regime. A well-designed industrial slab combined with a correctly specified protective resurfacing layer can offer many years of use if spills are cleaned promptly and the floor is inspected regularly. We can advise on appropriate maintenance, help set simple inspection routines and plan periodic repairs so that small issues are addressed before they become more significant.

Flooring Solutions for Hazardous Material Storage (HAZMAT) Facilities