Warehouse flooring case study · Rhondda, South Wales
Superior Resin Solutions refurbished approximately 5,000m² of neglected
warehouse flooring for a manufacturing company taking over an industrial unit
in Rhondda. The project combined extensive mechanical preparation, concrete
repairs and an oil-tolerant Vebro Polymers epoxy system, delivered in two phases
over two weeks.
The project brief
The industrial building in Rhondda had been standing empty for around two
years. The warehouse floor itself had been neglected for considerably longer
and was in poor condition when the new manufacturing company took over the unit.
Across the approximately 5,000m² slab, the existing surface contained
oil contamination, cracks, holes, areas of old resin, worn concrete
and previous damage.
The requirement was not simply to make the floor look better. The substrate
needed to be properly prepared and repaired before installing a flooring system
suitable for the manufacturing company’s use of the building.
Project challenge:
contamination and long-term deterioration meant that the preparation,
repairs and primer selection were just as important as the final epoxy coats.
Before and after
The photographs provide genuine visual evidence of the condition SRS inherited
and the finished warehouse floor after preparation, repairs, priming and coating.
Before
The existing floor showed years of wear, old coatings, contamination and
damaged areas that needed addressing before the new system could be installed.
After
The completed Vebro Polymers system produced a clean Glorious Grey
industrial finish with aluminium oxide incorporated into the final coat.
Preparation and repairs
The floor required substantial preparation before any primer or epoxy coating
could be considered.
SRS used a combination of diamond grinding and shot blasting
across suitable areas. Using the two preparation methods allowed the team to
tackle the condition of the existing floor efficiently while creating the
mechanically prepared substrate required for the new resin system.
There were also numerous cracks, holes and areas of old resin.
These defects were cleaned and prepared before being repaired using a
resin repair mortar.
Read more about this stage on our
Industrial Floor Preparation and Repairs
page.
Flooring specification
Oil was present within the existing concrete, so the primer stage needed
to reflect the actual condition of the substrate rather than treating this
as a straightforward clean concrete floor.
SRS installed Vebro EP OT Primer, followed by
two coats of Vebro EP Universal in
Glorious Grey.
Each Vebro EP Universal coat was applied at approximately
350 microns. Aluminium oxide was incorporated into the
final coat to provide a slight anti-slip finish.
Oil-tolerant epoxy primer selected because oil contamination was present
in the existing slab.
Vebro Polymers
Vebro EP Universal installed in Glorious Grey at approximately
350 microns.
Vebro Polymers
A second coat of Vebro EP Universal installed at approximately
350 microns to complete the high-build epoxy finish.
Glorious Grey
Aluminium oxide incorporated into the final coat to give the
warehouse floor a slight anti-slip texture.
Final coat
The installation process
The full flooring package was divided into two phases at the client’s request
and completed across a two-week programme.
Review the existing slab, oil contamination, old resin, cracks, holes,
damage and working programme.
Diamond grind and shot blast the floor to remove unsuitable material
and mechanically prepare the concrete.
Prepare cracks, holes and damaged areas before rebuilding them with
resin repair mortar.
Apply the Vebro EP OT Primer and two EP Universal coats before
completing the slight anti-slip finish.
Project results
The project converted a heavily neglected industrial floor into a clean,
consistent and serviceable epoxy surface ready for the manufacturing company
taking over the building.
A substantial warehouse floor refurbished across two planned phases.
The presence of oil influenced the primer specification rather than
being ignored beneath the new coating.
After completion, the client immediately asked SRS for pricing for
additional rooms at the facility.
Genuine project photographs
All photographs below are from this 5,000m² SRS warehouse flooring project.
Client feedback
“Floor looks to have dried ok and looking nice. Could do with the quote for the other rooms ASAP as need to submit option.”
Manufacturing client · Rhondda, South Wales
Message received after completion of the warehouse flooring package.
The message was brief, but it provided two useful pieces of feedback:
the completed floor was looking good and the client wanted SRS to price
additional rooms straight away.
Related SRS services
This project combines several of the services SRS provides for
warehouses, manufacturing facilities and other industrial environments.
Diamond grinding, shot blasting, coating removal and concrete floor
repairs before resin installation.
Resin flooring for logistics, manufacturing, storage, forklift routes
and warehouse refurbishment projects.
Epoxy flooring systems for suitable industrial and commercial
concrete floors.
Heavy-duty resin flooring solutions for factories, warehouses,
workshops and manufacturing environments.
Practical resin flooring for manufacturing, engineering and busy
industrial working areas.
Explore verified resin flooring projects completed by Superior Resin Solutions.
Project FAQs
Key details from the 5,000m² industrial flooring refurbishment.
The flooring package covered approximately 5,000m² of warehouse
floor in Rhondda, South Wales.
The client requested the work to be divided into two phases. SRS
completed the full flooring package across a two-week programme.
Preparation included both diamond grinding and shot blasting.
Cracks, holes, damaged areas and old resin remnants were also prepared
before repair and coating.
Damaged areas were prepared and repaired using a resin repair mortar
before installation of the primer and epoxy coating system.
SRS used Vebro EP OT Primer, an oil-tolerant primer selected because
oil contamination was present within the existing concrete slab.
Following the Vebro EP OT Primer, SRS installed two coats of Vebro
EP Universal in Glorious Grey at approximately 350 microns per coat.
Yes. Aluminium oxide was incorporated into the final coat to provide
a slight anti-slip finish for the warehouse floor.
Yes. After confirming that the completed floor was looking good,
the client asked SRS to provide a quotation for additional rooms
as soon as possible.
Plan your industrial floor refurbishment
Send the site location, approximate floor area, clear photographs,
existing floor condition, traffic and required programme. SRS can review
the information and discuss the most practical preparation and resin
flooring route.
Superior Resin Solutions UK Ltd provides industrial, commercial and domestic resin flooring across South Wales and the UK. We install durable epoxy, polyurethane, anti-slip, warehouse, factory, food-grade and resin bound systems for businesses, homes and commercial sites.