Manufacturing flooring case study · Caerphilly

240m² Manufacturing Resin Flooring Caerphilly – Eriez Magnetics Europe

Superior Resin Solutions upgraded a 240m² former workshop floor at
Eriez Magnetics Europe in Caerphilly for its change to manufacturing use.
The six-day flooring programme included planetary diamond grinding,
epoxy repairs, two primer stages, a 3mm self-levelling epoxy system,
two heavy-duty matt PU sealer coats, an anti-slip finish and
reinstatement of the PU floor joints.

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240m² manufacturing area
3mm self-levelling epoxy
RAL 7035
Matt PU anti-slip finish
6-day installation
7-day shutdown

240
m²

Manufacturing floor area
Former workshop converted for manufacturing use.

3
mm

Self-levelling epoxy
Installed over the prepared and repaired substrate.

6
DAY

Six working days
Completed inside a seven-day shutdown window.

RAL
7035

Light-grey finish
Two matt PU sealer coats with anti-slip in the final coat.

The project brief

Preparing an old workshop floor for manufacturing use

Eriez Magnetics Europe was changing this 240m² area in
Caerphilly from workshop use to manufacturing. The existing old
concrete and resin flooring was no longer suitable for the planned
use and needed a full preparation-led upgrade.

There were also small cracks and holes to repair, along with existing
floor joints that needed to be correctly reinstated after the new
resin flooring system was completed.

SRS had a seven-day shutdown window. That period had to cover
preparation, priming, resin installation, sealing, joint
reinstatement and the curing time needed before the area returned
to service.

Old concrete and existing resin finish
Workshop changing to manufacturing use
Small cracks and holes requiring epoxy repair
PU floor joints requiring reinstatement
Seven-day shutdown including curing time
Cold January temperatures to manage

Project date:
the flooring works started on 15 January 2024 and were completed
inside the planned shutdown.

Before and after

From an ageing workshop floor to a manufacturing resin floor

The project photographs show the change from the previous workshop
surface to the completed RAL 7035 resin flooring system.

Before & after

Main floor transformation

Comparison of the existing workshop floor with the new
self-levelling resin surface.

Before & after

Roller-door area upgraded

The completed RAL 7035 finish extends across the manufacturing
area and towards the roller doors.

Installed flooring system

3mm self-levelling epoxy with a two-coat matt PU finish

The manufacturing floor was built around mechanical preparation,
epoxy repairs, two primer stages, a 3mm self-levelling epoxy layer
and two heavy-duty matt polyurethane sealer coats.

Planetary diamond grinding

A four-head planetary grinder with fast-fit diamond tooling
mechanically prepared the existing floor.

Epoxy repairs and priming

Small cracks and holes were repaired with epoxy repair material
before the first and second primer stages.

3mm self-levelling epoxy

The self-levelling epoxy body layer was installed across the
prepared 240m² manufacturing floor.

PU seal and anti-slip finish

Two heavy-duty matt PU sealer coats completed the system, with
anti-slip added to the second coat.

Six-day installation programme

Flooring completed inside the seven-day shutdown

Each stage was sequenced around the shutdown window and the curing
requirements of the resin flooring system.

Day 1

Prepare and first prime

Planetary diamond grinding, floor preparation, local epoxy repairs
and the first primer stage.

Day 2

Second primer

The second primer stage prepared the substrate for the
self-levelling epoxy installation.

Day 3

Install 3mm epoxy

The 3mm self-levelling epoxy body layer was installed across the
240m² area.

Day 4

First PU sealer

The first heavy-duty matt polyurethane sealer coat was applied
over the cured epoxy.

Day 5

Second seal + anti-slip

The second matt PU coat was installed with the additional
anti-slip finish.

Day 6

Reinstate PU joints

The joints were cut and the polyurethane floor joints reinstated
to finish the package.

Cold-weather installation

Managing floor temperature and curing in January

The flooring works started on 15 January 2024, so the winter
temperatures created an additional programme consideration.

SRS hired heaters to increase both the temperature inside the unit
and the floor temperature. This helped create suitable conditions
for the installation stages and allowed the required curing periods
to be managed inside the seven-day shutdown.

The programme could not be judged only by the six physical working
days. The final handover also needed to account for curing before the
manufacturing area returned to use.

Why it mattered:
the shutdown included the flooring works and curing time, so ambient
and substrate temperature had to be managed as part of the programme.

Completed self levelling epoxy manufacturing floor at Eriez Magnetics Europe — Completed resin floor following the January installation and curing programme

The completed result

A new RAL 7035 manufacturing floor completed in six working days

The completed project gave Eriez Magnetics Europe a new self-levelling
resin floor for the area’s move from workshop use to manufacturing.

240m²

Full area upgraded

The complete 240m² area received preparation, local repairs,
resin flooring and PU protection.

3mm

Self-levelling epoxy

A 3mm self-levelling epoxy layer formed the main resin flooring build.

Matt anti-slip finish

Two heavy-duty matt PU sealer coats protected the floor, with
anti-slip added to the final coat.

6 DAY

Shutdown programme met

The physical flooring programme was completed over six working
days inside the seven-day shutdown.

Wide view of completed RAL 7035 manufacturing resin flooring at Eriez Magnetics Europe — Wide view of the completed RAL 7035 manufacturing floor

Finished light grey manufacturing resin flooring at Eriez Magnetics Europe in Caerphilly — Finished self-levelling epoxy and matt PU-sealed surface

Client feedback

Eriez Magnetics Europe on the completed flooring project

“Highly recommend this team. A few things stood out during our project:

Speed & Quality: Work was completed quickly without compromising on a high standard.

Communication: The transaction from quote to completion was smooth and effortless.

Workmanship: Extremely professional and kept the site clean throughout.

We will definitely be using them again.”

Lee James — Operations Manager, Eriez Magnetics Europe

Client feedback following completion of the Caerphilly flooring project

Genuine client feedback retained by SRS

Following the feedback, Lee also said he had passed SRS’s number to the
maintenance manager regarding another area requiring flooring work.

Related flooring services

Planning a manufacturing, factory or workshop floor upgrade?

Explore the SRS services connected with this project or send us the
floor area, site location, photographs, current condition and
shutdown requirements.

Manufacturing flooring FAQs

Questions about the Eriez Magnetics Europe project

What flooring system was installed at Eriez Magnetics Europe?

SRS installed a 3mm self-levelling epoxy flooring system followed
by two coats of heavy-duty matt PU sealer. Anti-slip was added to
the final sealer coat.

How large was the Caerphilly manufacturing floor?

The project covered approximately 240m² inside a former
workshop area being changed to manufacturing use.

How was the old floor prepared?

SRS used a four-head planetary grinder fitted with fast-fit
diamond tooling. Small cracks and holes were then repaired using
epoxy repair material.

How long did the flooring installation take?

The physical flooring programme was completed over six working
days inside a seven-day shutdown window that also needed to
accommodate curing time.

How were the cold January conditions managed?

Hired heaters were used to raise both the unit temperature and
the floor temperature so installation and curing could be managed
within the shutdown programme.

What happened to the existing floor joints?

The joints were cut and the polyurethane joints reinstated on
day six after the flooring and sealer stages were completed.

Planning a manufacturing floor upgrade?

Tell SRS how the floor will be used and how much shutdown time is available

Send the site location, approximate floor area, photographs,
existing floor condition, traffic, manufacturing requirements and
available shutdown period. SRS can review the project and discuss
the next step.

Send Project Details