Case Study: Industrial Warehouse Rubber Flooring | 3,500m² Distribution Centre, Birmingham
Project Overview: Complete heavy-duty rubber flooring installation for a 3,500m² logistics distribution centre in Birmingham, handling 24/7 operations with constant forklift traffic and heavy goods movement.
The Challenge
A major third-party logistics (3PL) provider was relocating to a new distribution centre in Birmingham and needed industrial-grade flooring that could withstand:
- Heavy forklift traffic: 12+ forklifts operating continuously across 3 shifts
- Point loading: Pallet racking with loads up to 15 tonnes per bay
- Chemical exposure: Occasional oil, grease, and cleaning chemical spills
- Anti-slip requirements: HSE compliance for worker safety in all conditions
- Noise reduction: Minimising operational noise for nearby workers
- Fast installation: Only 2 weeks before operational handover
Our Solution
After a detailed site assessment, we specified our heavy-duty industrial rubber flooring system, combining different products for optimal performance in each zone:
| Zone | Product | Area | Specification |
|---|---|---|---|
| Main Warehouse Floor | 6mm Studded Rubber Sheeting | 2,500m² | Forklift rated |
| Loading Docks | 10mm Heavy Duty Anti-Slip | 400m² | Oil resistant |
| Walkways & Aisles | 4mm Ribbed Rubber Matting | 350m² | High visibility |
| Packing Area | 6mm Anti-Fatigue Matting | 250m² | Worker comfort |
Installation Process
Our specialist industrial flooring team completed the installation over 10 working days, working night shifts to avoid disrupting the clients setup activities:
- Days 1-2: Concrete floor preparation, crack repair, and moisture testing
- Days 3-5: Main warehouse floor installation (2,500m²)
- Days 6-7: Loading dock areas with heavy-duty specification
- Days 8-9: Walkways, aisles, and packing stations
- Day 10: Edge sealing, transition strips, and HSE inspection
Product Specifications
| Specification | Detail |
|---|---|
| Material | High-density SBR rubber compound |
| Thickness | 4mm – 10mm (zone dependent) |
| Load Rating | Up to 15 tonnes point load |
| Slip Resistance | R11 rated (wet & dry conditions) |
| Temperature Range | -30°C to +80°C |
| Chemical Resistance | Oils, greases, most industrial chemicals |
| Fire Rating | Bfl-s1 (EN 13501-1) |
| Warranty | 10 years commercial/industrial use |
Results
"We evaluated several flooring options including epoxy coatings and PVC tiles. The rubber flooring solution from Slip-Not was the clear winner on durability, installation speed, and total cost of ownership. After 6 months of heavy use with 12 forklifts running 24/7, the floor shows virtually no wear. Our accident rate has dropped significantly thanks to the anti-slip properties, even in wet conditions near the loading docks."
— Operations Director, Birmingham Distribution Centre
Key Benefits:
- ✅ Zero forklift-related floor damage after 6 months of 24/7 operation
- ✅ 40% reduction in slip incidents compared to previous facility
- ✅ Significant noise reduction improving worker environment
- ✅ Easy cleaning with industrial scrubber-dryers
- ✅ No downtime during installation (night shift work)
- ✅ Full HSE and ISO 45001 compliance documentation
Project Summary
| Detail | Value |
|---|---|
| Location | Birmingham, West Midlands |
| Total Area | 3,500m² |
| Installation Time | 10 working days (night shifts) |
| Products Used | Studded rubber, ribbed matting, anti-fatigue |
| Completion Date | November 2025 |
Start Your Warehouse Flooring Project
We supply heavy-duty industrial rubber flooring for warehouses, factories, and distribution centres across the UK. Free delivery on orders over £150.
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Need a quote? Call 01744 520110 or email sales@slip-not.co.uk
