Warehouse flooring case study · Rhondda, South Wales

5,000m² Warehouse Resin Flooring Refurbishment in Rhondda

Q: How large was the Rhondda warehouse flooring project?

The flooring package covered approximately 5,000 square metres within a newly acquired industrial unit for a major South Wales manufacturer.

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 flooring system, delivered in phases across a demanding two-week programme.

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Approx. 5,000m²
Diamond grinding
Shot blasting
Vebro epoxy system
Two-week phased programme

Project snapshot

5,000m²

Major warehouse refurbishmentApproximately 5,000m² of industrial flooring for a South Wales manufacturer.

PREP

Diamond grinding and shot blastingTwo mechanical preparation methods used across suitable areas of the warehouse slab.

EPOXY

Vebro Polymers epoxy flooring systemVebro EP OT Primer followed by two coats of Vebro EP Universal in Glorious Grey.

2 weeks

Phased programmeThe manufacturer began moving machinery and installing racking in completed areas while SRS continued the remaining works.

The project brief

Recovering a badly deteriorated warehouse floor for expansion

The client, a major South Wales manufacturer, had purchased the industrial unit to provide additional space as its business expanded.

The warehouse provided the extra capacity required, 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 the remaining flooring works.

Old resin flooring showing extensive deterioration
Oil contamination across areas of exposed concrete
Cracks, holes and damaged substrate requiring repair
Tight programme linked to the manufacturer’s move into the building

Key principle: this was not a cosmetic recoating project. The success of the new epoxy flooring depended on dealing correctly with contamination, failed coatings and damaged concrete underneath it.

Before and after

A complete 5,000m² warehouse floor transformation

The photographs show the condition of the inherited floor and the clean Glorious Grey epoxy finish achieved after extensive preparation, repairs and installation of the Vebro Polymers flooring system.

Before

Failed resin and damaged concrete

The inherited floor contained deteriorated coatings, worn concrete, oil-affected areas, cracking and extensive defects requiring preparation and repair.

After

Completed Glorious Grey epoxy warehouse resin flooring in Rhondda South Wales

Glorious Grey industrial epoxy finish

The completed floor provided a consistent epoxy surface with aluminium oxide incorporated into the final coat for additional slip resistance.

Installed flooring system

Vebro Polymers epoxy flooring system

The flooring build-up was selected around the actual condition of the slab, including failed resin, oil contamination, cracking and areas of damaged concrete.

ManufacturerVebro Polymers

PrimerVebro EP OT Primer

Epoxy build-upTwo coats of Vebro EP Universal in Glorious Grey, approximately 350 microns per coat

FinishAluminium oxide incorporated into the final coat for additional slip resistance

Mechanical preparation

Diamond grinding and shot blasting were used across suitable areas to remove failed material and create the mechanically prepared surface required for the new epoxy system.

Epoxy substrate repairs

Damaged areas were rebuilt using epoxy repair mortars. Suitable surface cracks were treated using resin modified with a thixotropic thickening agent where required.

Vebro EP OT Primer

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

Two epoxy coats and anti-slip finish

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

Phased installation around the manufacturer’s move-in

The warehouse was not operational when SRS started, but the programme was planned so the manufacturer could begin setting up completed areas while the remaining flooring works continued.

Assess

The team reviewed the failed resin, oil-affected concrete, substrate damage, cracking and the manufacturer’s required programme.

Prepare

Diamond grinding and shot blasting removed unsuitable material and mechanically prepared appropriate areas of the warehouse slab.

Repair

Damaged concrete was rebuilt using epoxy mortars, with suitable surface cracks treated using thixotropic resin repair methods.

Install and phase

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

A repaired epoxy warehouse floor ready for expansion

The 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

Approx. 5,000m² completed

A substantial epoxy flooring package completed across the manufacturer’s newly acquired warehouse.

BASE

Substrate defects repaired

Cracks, holes and damaged areas were treated before the new system was installed rather than simply being concealed.

PHASE

Client setup kept moving

Machinery and racking installation began in completed Phase 1 areas while SRS continued the remaining flooring works.

Further work requested

Following completion, the manufacturer asked SRS to provide pricing for additional rooms within the facility.

Warehouse floor before and after epoxy flooring refurbishment in Rhondda South Wales — Genuine before-and-after view showing the scale of the warehouse flooring refurbishment

Completed warehouse epoxy resin flooring transformation for South Wales manufacturer — Completed Glorious Grey epoxy finish across the manufacturer’s warehouse

Client feedback

The next flooring areas were already being discussed

“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

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Warehouse flooring FAQs

Questions about the Rhondda warehouse refurbishment

How large was the Rhondda warehouse flooring project?

The flooring package covered approximately 5,000m² within a newly acquired industrial unit for a major South Wales manufacturer.

What condition was the existing warehouse floor in?

The floor contained badly deteriorated old resin flooring, oil-affected concrete, cracking, holes and numerous damaged areas within the underlying substrate.

How was the floor mechanically prepared?

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.

How were cracks and damaged concrete repaired?

Larger damaged areas were repaired using epoxy repair mortars. Suitable surface cracks were treated using resin modified with a thixotropic thickening agent where required.

What Vebro Polymers flooring system was used?

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.

Why was an anti-slip finish incorporated?

Aluminium oxide was incorporated into the final coat as an additional safety measure for the number of employees expected to use the manufacturing facility.

How did SRS work around the manufacturer’s move into the warehouse?

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.

Did the manufacturer ask SRS to complete more flooring work?

Yes. Following completion of the warehouse flooring, the client asked SRS to provide pricing for additional rooms within the same facility.