Epoxy & Resin Flooring RAMS: A Complete Guide for Industrial Flooring Contractors (2026)

Table of Contents

• Why Resin Flooring RAMS Matter
• Key Hazards in Resin Floor Installation
• Surface Preparation: Diamond Grinding and Shot Blasting
• COSHH Overview: Isocyanates, Epoxy Resins, and Solvents
• Ventilation Requirements for Resin Application
• CDM 2015 Obligations for Resin Floor Contractors
• What Your Resin Flooring RAMS Must Cover
• Frequently Asked Questions
• Next Steps

Why Resin Flooring RAMS Matter

Epoxy and polyurethane resin flooring is widely used in industrial units, food processing facilities, pharmaceuticals, commercial kitchens, and healthcare environments. The installation process involves hazardous chemicals — including isocyanates in polyurethane systems and epoxy resins in two-component flooring — that require thorough COSHH assessment and strict exposure controls.

Under CDM 2015, resin flooring contractors are duty holders who must produce a project-specific RAMS before installation begins. On industrial and commercial projects, principal contractors have become more rigorous in their review of flooring RAMS because the COSHH risks — particularly from isocyanates — are potentially life-changing and the consequences of inadequate controls are well documented.

This guide explains what a compliant epoxy resin flooring RAMS must include for 2026 projects, with a particular focus on the chemical hazard controls that are most frequently inadequate in submitted documents.

Browse all trade RAMS templates on the RAMS AI trade hub — covering 22 specialist construction trades.

Key Hazards in Resin Floor Installation

Your risk assessment must identify all significant hazards. For resin flooring work, these typically include:

• Chemical exposure — isocyanates — Polyurethane resin systems contain isocyanates (typically MDI or HDI). Isocyanates are the largest single cause of occupational asthma in the UK. Sensitisation can result in lifelong disability. The HSE regards isocyanate exposure as one of the most serious COSHH risks in construction.
• Chemical exposure — epoxy resins — Two-component epoxy flooring systems contain epoxy resin (skin and respiratory sensitiser) and amine hardeners. Both components can cause occupational dermatitis and, in poorly ventilated environments, respiratory symptoms.
• Solvent exposure — Many resin flooring systems use solvent-based primers, thinners, and surface treatment products. Solvents present flammable atmosphere, narcosis, and chronic nervous system hazard risks.
• Surface preparation hazards — Diamond grinding and shot blasting of concrete substrates generates silica dust. This is a COSHH risk requiring engineering controls and potentially RPE.
• Manual handling — Resin flooring materials (buckets of resin, bags of aggregate, shot blast equipment) are heavy and awkward. Manual handling risk assessments must address weights, carrying routes, and mechanical handling aids.
• Slip and fall during application — Mixed resin is extremely slippery before curing. Your RAMS must address how work areas are demarcated and how the principal contractor and other trades are prevented from walking on uncured resin.
• Fire hazard from solvent-based products — Some primers and thinners are flammable liquids (Class B) requiring hot works permits and solvent storage controls.

Surface Preparation: Diamond Grinding and Shot Blasting

Proper surface preparation is critical to resin flooring performance — and it generates two significant hazards that must be addressed in your RAMS before resin application begins:

• Silica dust from concrete preparation — Diamond grinding and shot blasting of concrete substrates generates respirable crystalline silica (RCS). Your COSHH assessment must confirm that:
  • Diamond grinders are fitted with on-tool dust extraction (H-class vacuum unit)
  • Shot blast recirculation systems have effective dust collection
  • RPE (FFP3 minimum, or P3 filter half-mask for longer operations) is worn during preparation
  • The work area is segregated from other trades during preparation
• Noise from grinding equipment — Diamond grinding and shot blasting can generate noise levels of 85 to 105 dB(A). Your RAMS must specify the noise level of the equipment being used (obtain from manufacturer), confirm that noise assessments have been made, and specify hearing protection for all operatives and anyone in the vicinity during preparation.

Your method statement must describe the preparation specification — CSP (Concrete Surface Profile) required for the system being applied — and how the substrate will be assessed and recorded before priming.

COSHH Overview: Isocyanates, Epoxy Resins, and Solvents

Resin flooring contractors must produce individual COSHH assessments for every hazardous product used. The key hazard categories are:

• Isocyanates (polyurethane systems) — The WEL for MDI is 0.02 mg/m³ as an 8-hour TWA. This is a very low limit that is easily exceeded in poorly ventilated environments. The mandatory controls are: adequate ventilation (see below), suitable RPE (A2P3 half-mask or higher), nitrile gloves, and health surveillance. The HSE's EH40 guidance on isocyanates must be referenced in your COSHH assessment.
• Epoxy resin (two-component systems) — Controls include nitrile gloves (minimum 0.2 mm), eye protection, general or forced ventilation, and health surveillance for frequent users.
• Hardeners and curing agents — Amine hardeners in epoxy systems are corrosive and may be respiratory sensitisers. Specific controls must be drawn from the product SDS.
• Solvents — Specify flash point, LEL concentration in air, ventilation requirement, and RPE for organic vapour exposure (A-type filter).

All COSHH assessments must be product-specific and reference the current SDS. Generic chemical hazard descriptions are not adequate.

Ventilation Requirements for Resin Application

Adequate ventilation is the most critical engineering control for resin flooring COSHH. Your RAMS must specify:

• Whether natural ventilation is adequate for the application environment — in enclosed industrial units without opening windows or doors, it is almost never adequate
• The type of forced ventilation to be used: temporary fans, LEV units, or HVAC system operation
• The minimum air change rate required for the specific product and application area (obtain from the manufacturer's application guide)
• Whether a continuous atmospheric monitoring programme is required (typically for large areas with polyurethane systems)
• The exclusion zone around the application area and the control measures for preventing other trades from entering the area during application and initial cure

For particularly large applications or enclosed spaces, a specialist occupational hygienist may be required to assess ventilation adequacy and confirm that the proposed controls will keep exposure below the WEL.

CDM 2015 Obligations for Resin Floor Contractors

Resin flooring contractors on commercial and industrial projects are contractors under CDM 2015. Key obligations include:

• Producing a project-specific RAMS covering the actual products being used, the actual surface preparation method, and the specific building environment
• Submitting the RAMS to the principal contractor and waiting for written approval before mobilisation
• Briefing all operatives on the RAMS content, with attendance records
• Ensuring health surveillance records are current for operatives working with isocyanates
• Reporting any near misses or significant changes to the application method

What Your Resin Flooring RAMS Must Cover

• Resin system type, manufacturer, product data sheet references
• Surface preparation method: diamond grinding or shot blasting specification, CSP target
• COSHH assessments for all products: resin, hardener, primer, aggregate, solvent-based products
• Ventilation specification: natural vs forced, air change rate, monitoring requirements
• PPE schedule: gloves, eye protection, RPE type and filter classification for each product
• Health surveillance arrangements for isocyanate exposure
• Silica dust controls during surface preparation: LEV or on-tool extraction, RPE
• Noise assessment for grinding and shot blast equipment
• Exclusion zone management during application and cure
• Solvent storage and flammable materials controls
• Manual handling assessment for bulk materials
• Slip hazard management for uncured resin areas
• Emergency procedures and nearest first aid location
• CDM pre-start briefing record

Frequently Asked Questions

Do we need health surveillance for all operatives who use epoxy flooring products?

Health surveillance is required where there is a reasonable likelihood of occupational disease from exposure to hazardous substances. For isocyanates, the HSE requires health surveillance for all workers regularly exposed — including a pre-employment health questionnaire and periodic health checks. For epoxy resins, health surveillance is required where there is a risk of occupational skin disease or asthma. In practice, most resin flooring contractors should have formal health surveillance programmes for their installation operatives.

What RPE is required for polyurethane resin flooring application?

For polyurethane systems containing MDI or HDI isocyanates, the minimum RPE is typically an A2P3 combination filter half-mask, which protects against both organic vapours (A2) and particulates including aerosols (P3). In high-spray applications, a powered air-purifying respirator (PAPR) with A2P3 filters provides a higher assigned protection factor and is recommended. Always confirm the RPE specification with the product manufacturer and the Operator exposure assessment.

What happens if another trade walks on our freshly applied resin?

Uncured resin is extremely difficult to remove from footwear and clothing, and contamination can spread throughout the building. More importantly, contamination of the resin surface during cure can compromise adhesion to subsequent coats. Your RAMS must specify the exclusion zone around the application area, the signage required, and the communication protocol with the principal contractor to prevent other trades entering the area. Curing times must be communicated to the principal contractor before application begins.

Next Steps

Your resin flooring RAMS is a critical document that must be specific to the products, environment, and application method for each project. RAMS AI generates comprehensive resin flooring risk assessments pre-populated with the chemical hazards and controls described in this guide.