Industrial Floor Conversion – Epoxy Industrial Flooring Case Study, Derbyshire

Introduction

A client in Derbyshire was converting an existing industrial area to a new use and needed the floor refurbished before installing racking. Years of use had left the concrete surface damaged, soiled and coated in a failing finish. Elgood Industrial Flooring was appointed to prepare the substrate, carry out resin repairs and install a Britdura 750 Industrial Solvent Free Epoxy Floor Coating, creating a hard wearing, slip resistant industrial floor in Slate Grey with Traffic Blue walkways, all completed within a five day programme.

Background

The industrial area had previously housed plant and equipment which had been stripped out as part of a wider conversion project. Once clear, the poor condition of the floor became obvious: the surface was damaged, soiled and coated in a system that had broken down in places, leaving weak patches and defects.

Before new racking and an updated layout could be installed, the client wanted a clean, robust industrial floor that would support safe storage, efficient material handling and straightforward cleaning. As British manufacturers and installers with more than a century of experience, Elgood Industrial Flooring was asked to deliver a complete refurbishment solution using an in house team and proven epoxy coating system.

The Challenge

The project needed to overcome several key issues:

• Refurbishing a damaged and soiled industrial floor so it was suitable for a new use and the installation of racking

• Removing weak and failing areas of the existing coating without damaging sound concrete beneath

• Repairing numerous localised defects in the slab using durable industrial strength resin repair materials

• Providing a consistent, well prepared surface ready to receive a high performance industrial floor coating

• Completing the refurbishment in just five days, from a Wednesday start to a Sunday finish, with the floor ready for scissor lift access the next day

The upgraded floor had to deliver long term performance, a clean professional appearance and a layout that clearly defined movement routes.

The Solution

Elgood Industrial Flooring designed and installed a complete refurbishment system built around thorough preparation and Britdura 750 Industrial Solvent Free Epoxy Floor Coating.

Key elements of the solution included:

• Vacuum contained diamond grinding
  The entire floor was prepared using vacuum contained diamond grinding to remove contamination and provide a uniform mechanical key. This dust controlled process helped maintain a cleaner working environment and ensured consistent adhesion for the new coating.

• Removal of weak coatings with PCD grinding
  Weak areas of the existing coating were removed using diamond grinders fitted with PCD (polycrystalline diamond) segments. These specialised tools efficiently stripped compromised material while protecting the underlying concrete where it remained sound.

• Industrial resin repairs
  Numerous localised defects and damaged areas were excavated and rebuilt using Elgood’s industrial strength resin repair material. This created a strong, level base across the floor, eliminating hollows and weak spots that could otherwise compromise the coating.

• Britdura 750 Industrial Solvent Free Epoxy Floor Coating
  The refurbished slab was coated with Britdura 750 Industrial Solvent Free Epoxy Floor Coating, applied to the client’s layout in Slate Grey with Traffic Blue for the walkway. The coating is applied by trowel to ensure an even distribution of resin and then finished by roller to achieve a consistent, fine slip resistant texture.

• In house installation and tight programme
  The entire installation was completed over five days, from Wednesday to Sunday, leaving the floor ready for scissor lifts the following day. All works were carried out by Elgood’s own small, full time in house team, giving the client a single point of responsibility and consistent workmanship throughout.

Outcome

The completed refurbishment has transformed the industrial floor in Derbyshire and prepared it for its new use:

• A clean, robust and slip resistant industrial floor ready for racking and daily operations

• A visually organised layout with Slate Grey production areas and Traffic Blue walkways to guide movement and support safety

• A surface repaired and strengthened with industrial resin materials, reducing the risk of future failures

• A high build, solvent free Britdura 750 epoxy coating offering long term durability and straightforward cleaning

• A fast, five day programme delivered by a British manufacturer installer using an experienced in house team

With the new industrial flooring system in place, the client has a dependable, professional quality floor that supports safe storage, efficient workflow and long term operational performance in the refurbished Derbyshire facility.