Manufacturing flooring case study · South Wales
Superior Resin Solutions refurbished approximately 5,000m² of severely
deteriorated warehouse flooring for a major South Wales manufacturer expanding
into a newly acquired industrial unit. The project combined extensive mechanical
preparation, substrate repairs and a Vebro Polymers epoxy system, delivered in
phases across a demanding two-week programme.
Major warehouse refurbishment
Approximately 5,000m² of industrial flooring
Two preparation methods
Diamond grinding combined with shot blasting
Oil-affected concrete
Primer specification selected around slab condition
Phased programme
Client began moving into completed areas during works
The project brief
The client, a major South Wales manufacturer, had purchased the industrial
unit to provide additional space as its business expanded.
The warehouse gave the company the extra capacity it needed, but the existing
floor presented a major refurbishment challenge. Large areas contained
old, heavily deteriorated resin flooring, while other sections
consisted of oil-affected concrete in a poor state of repair.
Beneath the failed surface, SRS encountered cracking, holes, worn concrete and
numerous damaged areas that could not simply be hidden beneath a new coating.
The substrate first had to be mechanically prepared and properly repaired.
Programme was equally important. Once Phase 1 was completed, the manufacturer
needed to begin moving machinery into the unit and installing racking while SRS
continued with the remaining flooring works.
Key principle:
this was not a cosmetic recoating project. The success of the new resin
flooring depended on dealing correctly with the existing contamination,
failed coatings and damaged concrete underneath it.
Before and after
The photographs show the condition of the industrial floor inherited by the
manufacturer and the clean Glorious Grey epoxy finish achieved after extensive
preparation, repairs and installation of the Vebro Polymers flooring system.
Before
The inherited floor contained deteriorated coatings, worn concrete,
oil-affected areas, cracking and extensive defects requiring preparation
and repair.
After
The completed floor provided a consistent new resin surface with aluminium
oxide incorporated into the final coat for additional slip resistance.
Installed flooring system
The new flooring build-up was selected around the actual condition of the
warehouse slab, including failed resin, oil contamination, cracking and
areas of damaged concrete.
01
Diamond grinding and shot blasting were used across suitable areas to
remove failed material and create the mechanically prepared surface required
for the new flooring system.
02
Damaged areas were rebuilt using epoxy repair mortars. Suitable surface
cracks were treated using resin modified with a thixotropic thickening
agent where required.
03
The oil-affected condition of sections of the existing concrete influenced
the primer specification, with Vebro EP OT Primer forming the first resin
layer.
Manufactured by Vebro Polymers
04
Two coats of Vebro EP Universal in Glorious Grey were applied at
approximately 350 microns per coat. Aluminium oxide was incorporated into
the final coat as an additional safety measure for employees using the facility.
Manufactured by Vebro Polymers
How the project was delivered
The warehouse was not operational when SRS started, but the programme was
phased so the manufacturer could begin setting up completed areas while the
remaining flooring works continued.
01
The team reviewed the failed resin, oil-affected concrete, substrate
damage, cracking and the manufacturer’s required programme.
02
Diamond grinding and shot blasting removed unsuitable material and
mechanically prepared appropriate areas of the warehouse slab.
03
Damaged concrete was rebuilt using epoxy mortars, with suitable surface
cracks treated using thixotropic resin repair methods.
04
The epoxy system was installed in phases, allowing machinery and racking
installation to begin in Phase 1 while SRS progressed Phase 2.
The completed result
The completed project transformed a badly deteriorated industrial floor into
a repaired and consistent epoxy surface while allowing the client’s wider
warehouse setup programme to continue.
AREA
A substantial industrial flooring package completed across the manufacturer’s
newly acquired warehouse.
BASE
Cracks, holes and damaged areas were treated before the new resin system
was installed rather than simply being concealed.
PHASE
Machinery and racking installation began in completed Phase 1 areas while
SRS continued the remaining flooring works.
MORE
Following completion, the manufacturer asked SRS to provide pricing for
additional rooms within the facility.
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.”
Major South Wales manufacturing client
Written feedback received following completion of the warehouse flooring package
Original client message retained by SRS
Related flooring services
Explore the SRS services relevant to projects involving failed resin flooring,
damaged concrete, industrial preparation and replacement epoxy systems.
Resin flooring for storage, distribution, manufacturing, forklift activity
and tired industrial concrete.
Preparation-led flooring systems for factories, warehouses, production
areas and demanding industrial environments.
Epoxy flooring selected around substrate condition, traffic, preparation
requirements and the required finish.
Resin flooring systems incorporating additional slip resistance for
appropriate industrial and commercial environments.
Durable industrial flooring for machinery, production, engineering and
workshop environments.
Industrial and commercial resin flooring services across South Wales
and surrounding areas.
Warehouse flooring FAQs
The flooring package covered approximately 5,000m² within a
newly acquired industrial unit for a major South Wales manufacturer.
The floor contained badly deteriorated old resin flooring, oil-affected
concrete, cracking, holes and numerous damaged areas within the underlying
substrate.
SRS used a combination of diamond grinding and shot blasting across
suitable areas to remove unsuitable material and mechanically prepare
the existing floor for repair and recoating.
Larger damaged areas were repaired using epoxy repair mortars. Suitable
surface cracks were treated using resin modified with a thixotropic
thickening agent where required.
The flooring build-up included Vebro EP OT Primer followed by two coats
of Vebro EP Universal in Glorious Grey at approximately 350 microns per coat.
Aluminium oxide was incorporated into the final coat as an additional
safety measure for the number of employees expected to use the
manufacturing facility.
The work was phased. After Phase 1 was completed, the manufacturer began
moving machinery into the finished area and setting up racking while SRS
continued with Phase 2.
Yes. Following completion of the warehouse flooring, the client asked SRS
to provide pricing for additional rooms within the same facility.
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.
