Pharmaceutical manufacturing flooring case study

3,725m² Pharmaceutical Resin Flooring South Wales – Multi-System Factory Case Study

This pharmaceutical resin flooring South Wales project involved approximately 3,725m² of resin flooring across an operational manufacturing facility. SRS installed 2mm self-levelling resin flooring, 600-micron high-build epoxy coating and 9mm heavy-duty polyurethane screed, together with approximately 640 linear metres of resin coving.

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3,725m² flooring programme
Pharmaceutical manufacturing
Cleanroom areas
640lm resin coving
Staged installations
South Wales

3,725
M²

Large-scale refurbishment
Multiple manufacturing and support areas

3
SYSTEMS

Three resin systems
Self-levelling, high-build epoxy and PU screed

640
LM

Resin coving
Epoxy and polyurethane coved detailing

PHASED

Operational factory
Individual areas completed to agreed deadlines

The project

Pharmaceutical Resin Flooring South Wales Across an Operational Factory

This pharmaceutical resin flooring South Wales project was a large multi-system refurbishment covering production, warehousing, cleanroom and supporting factory areas.

SRS worked across the facility over a series of planned phases rather than attempting to shut down the entire manufacturing operation at once.

Individual rooms and sections were released by the client when production allowed. SRS then prepared the substrate, completed the specified flooring system and returned each area within the agreed working window so the client’s manufacturing programme could continue.

The works covered production areas, warehousing, controlled white areas, cleanrooms, wash rooms, plant rooms and dehumidifier rooms.

Approximately 1,950m² of 2mm self-levelling resin flooring
Approximately 1,450m² of 600-micron high-build epoxy flooring
Approximately 325m² of 9mm heavy-duty polyurethane screed
Approximately 640 linear metres of resin coving
Diamond grinding used throughout the flooring programme
Minor cracks and small holes repaired where required
PU jointing compound installed to joints
Multiple phased installations around an operational pharmaceutical factory

Programme performance:
every flooring section was completed within the client’s agreed working window, with the phases handed back ahead of the required deadlines.

Pharmaceutical resin flooring South Wales project showing completed self-levelling resin flooring in a manufacturing corridor — Completed pharmaceutical resin flooring through a manufacturing corridor

System breakdown

Three Resin Flooring Systems Across One Pharmaceutical Manufacturing Facility

The different operating areas required different flooring build-ups. The specification therefore used three principal resin systems rather than applying one flooring type throughout the factory.

Flooring system	Approx. area	Build-up	Typical project areas	Manufacturer
Self-levelling resin flooring	1,950m²	2mm	Selected production, clean, controlled and circulation areas	Vebro Polymers
High-build epoxy flooring	1,450m²	Approx. 600 microns	Production, warehousing and supporting factory areas	Vebro EP HBC
Heavy-duty polyurethane screed	325m²	9mm	Selected heavy-duty manufacturing and process areas	Resdev Pumadur HF
Resin coving	Approx. 640 linear metres	Epoxy and PU coving	Floor-to-wall transitions across relevant areas	Matched to installed floor system

Multi-system specification

Why This Pharmaceutical Resin Flooring South Wales Project Needed More Than One System

A production corridor, warehouse area, cleanroom and heavy-duty process room do not necessarily place the same demands on a floor. The project therefore matched the flooring system to the requirements of each section.

1,950
M²

2mm Self-Levelling Resin

Vebro self-levelling resin flooring created a smooth seamless finish across substantial sections of the pharmaceutical manufacturing facility.

Vebro Polymers

1,450
M²

High-Build Epoxy Flooring

Vebro EP HBC was installed at approximately 600 microns across suitable production, warehouse and supporting manufacturing areas.

Vebro EP HBC

325
M²

9mm Heavy-Duty PU Screed

Resdev Pumadur HF polyurethane screed was installed at 9mm in light-grey and mid-grey finishes within selected heavy-duty areas.

Resdev Pumadur HF

1,950m² self-levelling installation

2mm Self-Levelling Resin Flooring for Pharmaceutical Production Areas

Approximately 1,950m² of the pharmaceutical resin flooring South Wales programme used a 2mm self-levelling resin system supplied by Vebro.

The flooring was installed through selected production rooms, corridors and controlled areas to create a smooth, seamless surface across multiple connected spaces.

The completed floors run continuously through doorways, room transitions and larger production spaces, providing a consistent resin finish throughout substantial sections of the facility.

Self-levelling resin flooring also formed part of the works within clean and controlled areas where disciplined housekeeping and contamination control were particularly important during installation.

View self-levelling resin flooring

Self-levelling resin flooring extending into a pharmaceutical manufacturing production room — 2mm self-levelling resin flooring through connected pharmaceutical manufacturing spaces

Glossy self-levelling resin floor across a large pharmaceutical manufacturing area — Large production area completed with seamless self-levelling resin flooring

Finished self-levelling resin flooring in a pharmaceutical manufacturing corridor — Smooth resin flooring through a pharmaceutical manufacturing corridor

Cleanroom and controlled white areas

Cleanroom Resin Flooring Within a Controlled Pharmaceutical Environment

Some phases of the project took place inside the client’s cleanroom and controlled white-area environments.

Personnel entering these areas were required to follow the site’s contamination-control procedures, including protective suits, hairnets and snoods.

Dust control, cleanliness and housekeeping were therefore important throughout the flooring works. SRS maintained clean and organised working areas while managing tools, materials and equipment within the client’s operational controls.

The resin flooring formed part of the client’s wider controlled environment. The flooring itself is not presented as independently creating or certifying a cleanroom.

This genuine cleanroom installation now provides strong project evidence behind our

hygienic and cleanroom flooring

service.

Cleanroom resin flooring within a controlled pharmaceutical manufacturing area — Seamless resin flooring installed within the pharmaceutical facility’s controlled environment

1,450m² high-build epoxy

Vebro EP HBC High-Build Epoxy Flooring Across Pharmaceutical Manufacturing Areas

Approximately 1,450m² of the pharmaceutical resin flooring South Wales project used a Vebro high-build epoxy system at approximately 600 microns.

The coating was installed through suitable production, warehousing and supporting operational areas where a high-build industrial epoxy finish was specified.

Several phases took place around established production equipment. Machinery and surrounding items were protected while SRS completed the agreed flooring section before handing the area back to the client.

This allowed substantial parts of the factory to be refurbished without requiring one prolonged site-wide production shutdown.

View industrial floor coatings

High-build epoxy flooring across a pharmaceutical manufacturing production area — Completed Vebro high-build epoxy flooring within a pharmaceutical production area

High-build epoxy flooring installed around protected pharmaceutical production machinery during a staged refurbishment — Production equipment protected during one of the staged high-build epoxy installations

High-build epoxy flooring beside protected machinery in a pharmaceutical production corridor — High-build epoxy installed around existing production equipment

325m² heavy-duty flooring

9mm Resdev Pumadur HF Heavy-Duty Polyurethane Screed

Selected parts of the pharmaceutical manufacturing facility required a more substantial flooring build-up than the self-levelling and high-build epoxy systems used elsewhere.

Approximately 325m² of Resdev Pumadur HF was installed at 9mm in light-grey and mid-grey finishes.

The heavy-duty polyurethane screed formed part of the wider multi-system programme and was completed within the same phased approach used across the factory.

PU jointing compound was also installed to joints where required as part of the flooring detailing.

View polyurethane screed flooring

9mm heavy-duty polyurethane screed flooring in a pharmaceutical manufacturing room — 9mm Resdev Pumadur HF heavy-duty polyurethane screed

640 linear metres

Epoxy and Polyurethane Resin Coving Across the Flooring Programme

Approximately 640 linear metres of resin coving were installed across the project, with the detailing matched to the flooring system used in each area.

Epoxy Coving

The self-levelling areas incorporated epoxy coving which was primed and coated to match the adjoining floor finish.

PU Coving

Polyurethane coving was installed to the relevant heavy-duty PU screed areas to continue the resin detail at floor-to-wall junctions.

Chemical-Resistant Finish

The polyurethane coving was overcoated with Resdev DD chemical-resistant coating as part of the specified finishing system.

Preparation and floor repairs

Diamond Grinding Throughout the Pharmaceutical Resin Flooring Project

Diamond grinding was used throughout the pharmaceutical resin flooring South Wales programme to mechanically prepare the existing substrates before installation of the new resin systems.

Preparation was particularly important because the project extended across thousands of square metres and several very different operating areas.

Minor cracks, small holes and local defects were repaired where required before the appropriate primer and flooring system was installed.

PU jointing compound was installed to joints where required as part of the completed flooring package.

View industrial floor preparation and repairs

Pharmaceutical resin flooring with coved perimeter and detailed doorway transition — Completed floor, doorway and perimeter detailing

Different factory environments

Production, Warehousing, Cleanrooms, Wash Rooms and Plant Areas

The scale of the pharmaceutical manufacturing site meant the flooring programme extended beyond one production room and covered several distinct operating environments.

PROD

Production Areas

Multiple operational production spaces were refurbished in planned sections around the client’s manufacturing programme.

CLEAN

Cleanrooms & White Areas

Controlled areas required particularly disciplined housekeeping, contamination control and management of dust during the works.

WASH

Wash Rooms

Wash-room areas formed part of the multi-system flooring package across the pharmaceutical facility.

PLANT

Plant & Dehumidifier Rooms

Supporting technical and plant spaces were also included within the phased flooring refurbishment programme.

Staged installation programme

Working Around Live Pharmaceutical Production Over Multiple Flooring Phases

The main project challenge was not simply installing resin flooring. SRS had to repeatedly complete and hand back individual areas within the client’s agreed production windows.

Agree Each Area

SRS coordinated with the client to identify which production room or factory section could be released and the required handover deadline.

Protect and Prepare

The working area was controlled, relevant equipment protected and the substrate prepared by diamond grinding before repairs and resin installation.

Install the Specified System

The required self-levelling resin, high-build epoxy or 9mm PU screed was installed together with the appropriate coving and joint detailing.

Hand Back the Area

Each phase was completed within the agreed window, with the areas finished ahead of the required handover deadlines.

Site control and housekeeping

Clean and Tidy Working Practices Were Critical in the Operational Factory

Working inside an operational pharmaceutical manufacturing site meant cleanliness and organisation were important throughout every phase.

SRS kept materials, equipment and tools controlled within the active work zones and paid particular attention to keeping access areas free from unnecessary clutter and trip hazards.

Dust control was especially important during work within and around the client’s cleanroom and white-area environments.

The project demonstrates that successful pharmaceutical flooring work is not only about the finished resin system. Planning, housekeeping, access control, programme management and communication with the client are also central to delivering each flooring phase safely and efficiently.

Protected pharmaceutical manufacturing equipment during a staged resin flooring installation — Production equipment protected during a staged flooring phase

Project results

3,725m² of Pharmaceutical Resin Flooring Delivered Across Multiple Factory Areas

The pharmaceutical resin flooring South Wales programme demonstrates how several resin technologies can be coordinated across one operational manufacturing facility.

1,950

Self-Levelling Resin

Approximately 1,950m² of 2mm seamless self-levelling resin flooring.

1,450

High-Build Epoxy

Approximately 1,450m² of 600-micron Vebro high-build epoxy flooring.

325

9mm PU Screed

Approximately 325m² of Resdev Pumadur HF heavy-duty polyurethane screed.

640
LM

Resin Coving

Approximately 640 linear metres of epoxy and polyurethane resin coving.

Self-levelling pharmaceutical resin flooring connecting multiple manufacturing rooms — Self-levelling resin flooring extending through multiple connected areas

High-build epoxy flooring around pharmaceutical production conveyor equipment — Industrial epoxy flooring around production equipment

Technical advice

Useful Resin Flooring Guides for Manufacturing and Pharmaceutical Projects

Several of the technical decisions involved in this project are covered in more detail within the SRS flooring advice library.

Related SRS services

Resin Flooring Services Used Across Projects Like This

This case study provides genuine project evidence for several of SRS’s specialist pharmaceutical, cleanroom and industrial flooring services.

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More Industrial and Manufacturing Resin Flooring Case Studies

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Project FAQs

Pharmaceutical Resin Flooring South Wales – Project FAQs

How large was this pharmaceutical resin flooring South Wales project?

The wider project covered approximately 3,725m² across three principal resin systems: around 1,950m² of self-levelling resin flooring, 1,450m² of high-build epoxy flooring and 325m² of 9mm polyurethane screed.

What resin flooring systems were installed?

The project used a 2mm Vebro self-levelling resin system, approximately 600-micron Vebro high-build epoxy flooring and 9mm Resdev Pumadur HF heavy-duty polyurethane screed.

Was resin flooring installed inside cleanroom areas?

Yes. Parts of the flooring programme took place inside the client’s cleanroom and controlled white-area environments where protective clothing and contamination-control procedures were required. The resin floor itself is not presented as independently creating or certifying a cleanroom.

How much resin coving was installed?

Approximately 640 linear metres of coving were completed across the project. Self-levelling areas received epoxy coving that was primed and coated to match the floor, while relevant polyurethane screed areas received PU coving with Resdev DD chemical-resistant coating.

How was the existing floor prepared?

Diamond grinding was used throughout the programme. Minor cracks, small holes and local defects were repaired where required before installation of the specified resin flooring system.

How did SRS work around the operational pharmaceutical factory?

The work was divided into numerous phases. SRS coordinated with the client to close individual areas, complete the required preparation and resin flooring within the agreed window and hand each section back ready for the manufacturing programme to continue.

Were the flooring phases completed on time?

Yes. Each section had an agreed deadline and SRS completed the flooring phases within the required windows, with the areas finished ahead of the agreed handover times.

Why were three different flooring systems used?

The factory contained production spaces, warehousing, cleanrooms, wash rooms, plant rooms and dehumidifier rooms with different flooring requirements. Using several resin systems allowed the specification to be matched to the requirements of each area.

Can SRS carry out pharmaceutical flooring in planned phases?

Yes, where the site, resin specification and programme allow it. This project demonstrates SRS working through numerous agreed phases within an operational pharmaceutical manufacturing environment.

Planning pharmaceutical resin flooring?

Discuss a Pharmaceutical Resin Flooring South Wales Project With SRS

For pharmaceutical, cleanroom or manufacturing flooring projects, send SRS your floor areas, room uses, existing floor condition, cleaning requirements, photographs and available shutdown windows. We can review the project area by area and help plan the appropriate resin flooring systems and installation sequence.

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