Industrial Floor Installation for Condale Plastics, Felbridge – Epoxy Flooring Case Study

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Introduction

Condale Plastics, a specialist plastic extrusion manufacturer based in Felbridge near East Grinstead, required a full upgrade of their main factory floor. Elgood Industrial Flooring had previously installed a Britdura 2000 solvent free epoxy resin floor in 2013, successfully overcoming historic contamination in the concrete. Ten years on, the existing industrial floor was still well adhered and in good condition, but the client wanted it refreshed and extended across the remaining untreated half of the factory, using the same proven specification.

Background

The original 2013 installation had been designed to deal with contamination in the concrete slab that had caused other floor systems to fail. While some osmotic pressure had produced the occasional small blister, the Britdura 2000 floor remained bonded and serviceable after a decade of use.

By 2023, Condale Plastics wanted to bring the rest of the production space up to the same standard and to give the existing floor a fresh, uniform appearance. The objective was to create a single, consistent industrial floor across approximately 1,200 m² of factory area, clearly defining production zones and gangways while maintaining slip resistance near roller doors.

The Challenge

The project brief included:

• Refurbishing a 10 year old epoxy industrial floor that was still performing but needed refreshing

• Preparing and coating the previously untreated half of the factory, where the concrete was in a different condition

• Managing historic contamination in the slab to ensure long term adhesion of the new flooring

• Introducing slip resistant finishes in areas close to roller doors for added safety

• Using colour to distinguish production areas and traffic routes, supporting safe, efficient operations

All of this had to be achieved in a live manufacturing environment, with minimal impact on day to day activity.

The Solution

Drawing on 125 years of industrial flooring experience and complete control over manufacturing and installation, Elgood Industrial Flooring designed and delivered a two part solution covering both the existing and untreated areas.

• Preparation of existing floor

  The existing epoxy floor was prepared by vacuum contained diamond grinding using a planetary grinder. This approach provided an even, well keyed surface and avoided the swirl marks that can occur with less controlled grinding techniques. Localised imperfections were addressed to ensure a sound base for the refresh coating.

• Preparation of previously untreated concrete

  The untreated half of the factory was prepared using a combination of vacuum contained shot blasting, diamond grinding with PCD teeth to remove weak and failed patches, and further planetary grinding where necessary. This sequence removed laitance and any weak material, leaving a clean, mechanically profiled surface ready for the new industrial flooring system.

• Refurbishment of existing floor

  The existing epoxy floor was refreshed using a trowel applied solvent free Epoxy High build Coating at just under 1 mm thickness. Despite being relatively thin, this high build system is extremely hard wearing and is ideal for renewing the appearance and performance of a sound industrial floor without unnecessary build up.

• New Britdura 2000 industrial flooring

  The previously untreated half of the factory received Elgood’s solvent free Britdura 2000 Epoxy Smoothing Flooring, the same specification successfully installed on the front half in 2013. Applied at around 2 mm thickness, Britdura 2000 provides a smooth, robust and chemically resistant industrial floor capable of withstanding heavy manufacturing use.

• Slip resistant safety zones

  A Grade 20 slip resistant finish was applied as a safety precaution towards the roller doors. This enhanced traction in areas where moisture or tracked in contamination might be more likely, helping to manage slip risk in busy access routes.

• Industrial floor layout and markings

  Dusty Grey and Charcoal were used to designate production areas and gangways respectively, creating an intuitive visual layout across the factory floor. Painted signs and markings were added to inform and reinforce safe operations, directing pedestrian and vehicle movements and supporting lean working practices.

All preparation and installation were carried out by Elgood’s own in house, full time installation team, ensuring consistent workmanship and a single point of responsibility from survey through to handover.

Outcome

The completed industrial floor installation has provided Condale Plastics with a unified, high performance working surface across the entire factory:

• A refreshed and extended Britdura based industrial floor system covering approximately 1,200 m²

• Proven performance on both the original and newly treated areas, with a specification already tested over 10 years in service

• Clearly defined gangways and production zones using Dusty Grey and Charcoal to improve safety and flow

• Targeted Grade 20 slip resistance towards roller doors, reducing slip risk in critical zones

• A clean, modern and professional appearance that reflects the quality of Condale Plastics’ manufacturing operation

By combining refurbishment of the original resin floor with a matching installation across the remaining space, Elgood Industrial Flooring has delivered a consistent, durable and visually coherent industrial floor that supports safe, efficient production for the long term.