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  • Writer's pictureKev Johnson

Polyurethane Resin Decking Transformed High End Gym Car Park: 4M Floors Case Study

Updated: Nov 15, 2023

As one of the leading resin flooring contractors, we at 4m Floors pride ourselves on our commitment to excellence. Our latest project, for a prestigious gym club, stands as a testament to our expertise in handling large-scale and intricate flooring solutions. This case study highlights the project's scope, challenges, and the impeccable execution of polyurethane resin decking in an exposed car park environment.


4m Floors UK - Your Resin Flooring Contractors

A big open car park with polyurethane resin coating

Polyurethane Resin Installation Overview

Tasked with the responsibility of revamping the top deck of an existing car park for a prestigious gym facility, we faced an array of challenges typical of an outdoor project of this scale. Our objective was to deliver a highly durable, weather-resistant, and visually appealing surface that could withstand the daily rigors of vehicle traffic and the unpredictable climate.

Challenges and Solutions

The top deck's exposure to the elements meant that the choice of material was critical. Epoxy resin, while popular for its strength and aesthetic finish, would not suffice for outdoor use due to its tendency to yellow under UV exposure. Instead, we opted for a polyurethane resin system known for its UV stability, flexibility, and resistance to weathering - the perfect fit for a high end gym club's needs.

Preparation: The Key to Durability

Top deck of a car park that has been prepared for resin installation

Understanding that the longevity of any decking solution begins with meticulous preparation, we embarked on an intensive surface preparation phase. This involved the use of industrial grinders to remove any old coatings and level the concrete surface, followed by thorough vacuuming to eliminate all traces of dust and debris. This process ensured optimal adhesion of the new resin system, which is crucial for enduring the test of time and use.

4m Floors UK have 30 experience of working on this type of project. We know that the key to an amazing polyurethane resin decking is good preparation of the surface.

Installation of Polyurethane Resin

The application of the polyurethane resin was conducted by our skilled team of technicians, trained in the art of precision and attention to detail. We worked diligently to mix and apply the resin, taking into account temperature and humidity levels to avoid any curing issues. Notably, the installation process included the following key practices:

  1. Batch Consistency: Ensuring every mix of polyurethane resin maintained consistency to avoid shade variations across the expansive area.

  2. Timely Application: Adhering to strict time frames for application after mixing, to guarantee perfect curing and bond strength.

  3. Quality Control: Continuously monitoring the application for any imperfections, such as air bubbles or uneven distribution.

Safety Considerations

In a car park, effective drainage is non-negotiable. We incorporated slope adjustments to facilitate water runoff and reduce slip hazards. Furthermore, we selected a decking with a non-slip texture to enhance safety - a critical factor given the gym members' varying age and fitness levels.

Final Outcomes

The completion of the car park decking project for a high end gym marked a significant achievement for 4m Floors. Not only did we deliver a solution that matched the gym's vibrant atmosphere, but we also provided a high-performance surface capable of withstanding the environmental stressors that an exposed deck encounters.


At 4m Floors, our commitment to using industry-leading materials like polyurethane resin, combined with our rigorous preparation and application processes, enables us to tackle challenging projects like this car park with confidence. We are proud to set benchmarks in the industry and look forward to continuing to serve our clients with flooring solutions that go above and beyond expectations.


4m Floors - Your Trusted Resin Flooring Contractors

At 4m Floors UK, we take pride in being a trusted name in resin flooring contractors, offering a comprehensive range of services tailored to large projects. From terrazzo installations to floor signage, manufacturing flooring, car park solutions, and food and beverage flooring, our expertise and versatility enable us to meet the unique needs of various industries. Contact us today to discuss your project requirements and experience the difference our quality resin flooring solutions can make.

If you have any questions please do get in touch at or alternatively give us a call on - 01782 576650


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