Introduction
Sunray Doors, part of the ASSA ABLOY group, required a full refurbishment of a 330 m² production area at their Ashford, Kent facility. With more than two decades of wear from heavy plant, trolleys and sustained operational use, the existing floor surface needed a high-performance, clearly marked, and long-lasting industrial floor system. Elgood Industrial Flooring was appointed to deliver a complete solution, manufacturing and installing a solvent-free epoxy floor finish that met ASSA ABLOY’s corporate colour standards while improving safety, workflow clarity and long-term performance.
Background
Sunray Doors specialises in the design and manufacture of high-security, high-performance doors across multiple sectors. Their Ashford facility operates to strict production and safety standards, meaning that the condition of the industrial floor plays an important role in both operational efficiency and workplace safety.
The existing floor had served the business for over 20 years. Although sound in parts, areas of surface abrasion, inconsistent colour coverage and ageing line markings were reducing visibility and overall floor quality. A modernised and durable industrial flooring system was required to restore performance and create a layout that supported the company’s production processes.
The Challenge
The project required:
• Minimising disruption to an active manufacturing site
• Achieving a unified and resilient finish across the entire 330 m² area
• Providing consistent corporate-aligned colours for gangways and production cells
• Delivering a solvent-free industrial flooring system suitable for regular heavy use
• Ensuring long-term slip resistance and ease of ongoing cleaning
Because the existing layout had evolved over many years, Sunray Doors also needed a clearer, more coherent flooring design that supported movement, safety and zoning of work areas.
The Solution
Elgood Industrial Flooring manufactured and installed the Britdura 2000 epoxy coating, a 2 mm thick, solvent-free system designed specifically for heavy industrial environments. As British manufacturers with 125 years of experience producing and installing industrial flooring, we were able to tailor the system precisely to the site’s operational conditions.
Key features of the solution included:
• Full mechanical preparation to ensure an even and long-lasting bond
• Britdura 2000 epoxy finish, providing durability, chemical resistance and a smooth but slip-resistant surface
• Colour-defined zones, with blue gangways and grey production cells, matching ASSA ABLOY’s standard requirements
• Improved layout clarity, making the working environment safer and easier to navigate
• Fast turnaround, reducing operational downtime
The installation team managed the full process in-house, ensuring complete quality control from preparation to final finishing.
Outcome
The refurbished industrial floor has transformed the production environment at Sunray Doors. The new system delivers:
• A stronger, cleaner and longer-lasting surface
• Greater visibility of routes and operational zones
• Improved safety through clear delineation and slip resistance
• A modern, professional appearance aligned with corporate standards
• Reduced maintenance requirements for the long term
With a durable and precisely installed industrial floor system, Sunray Doors now benefit from improved efficiency, enhanced safety and a surface designed to withstand many more years of continuous manufacturing activity.
