Introduction
Wallis Ltd required a cost-effective and hard-wearing industrial floor coating for its engineering facility in Nottingham. The existing 1,600 m² concrete floor was old, contaminated and heavily worn, with numerous potholes and cracks, so it needed significant preparation and remedial work before a new epoxy floor coating could be installed.
Elgood Industrial Flooring was appointed to prepare the floor, carry out repairs, install 600 m² of smoothing screed to resurface a particularly rough section and finish the full area with Britdura Solvent Free Highbuild Epoxy Floor Coating. The project was completed in two phases over a total duration of seven days to accommodate other trades working within the building, with the completed industrial floor ready for use the next day.
Background
Wallis Ltd needed an industrial floor that would support the practical demands of an engineering environment with forklift traffic. The floor varied greatly in condition, which meant the solution had to be tailored to get the best possible result from the existing concrete.
The floor was not simply worn. It also had contamination, cracks and potholes that needed to be dealt with before the new industrial floor coating could be installed. A particularly rough 600 m² section also required resurfacing with smoothing screed to create a better base for the final finish.
As British manufacturers and installers with more than 125 years of experience in industrial flooring, Elgood Industrial Flooring was able to provide a complete in-house solution. This included preparation, remedial work, smoothing screed and the installation of a solvent free highbuild epoxy floor coating suitable for an active engineering facility.
The Challenge
The project needed to address several clear requirements:
Seal and upgrade a 1,600 m² old and heavily worn concrete floor
Prepare a contaminated floor with numerous potholes and cracks
Provide a cost-effective industrial floor coating tailored to varying floor conditions
Resurface a particularly rough 600 m² section of the floor
Create a hard-wearing finish suitable for forklift traffic
Install a practical and visually improved floor finish for an engineering environment
Complete the works in two phases to accommodate other trades within the building
Return the industrial floor to use the next day
The Solution
Elgood Industrial Flooring specified and installed a complete industrial flooring solution for Wallis Ltd in Nottingham.
Key elements of the solution included:
Dust free shotblasting
Dust free shotblasting was used to prepare the existing concrete floor. This preparation method helped clean and profile the substrate, creating the correct surface for strong adhesion of the new industrial floor coating.
Diamond grinding to edges
Diamond grinding was used to prepare the floor edges. This helped ensure that the coating system could be installed neatly and consistently across the full floor area, including perimeter sections and detailed edges.
Remedial floor repairs
Before the new industrial flooring system was installed, remedial work was carried out across the floor. This included filling holes and general making good to address defects in the existing concrete and improve the condition of the substrate.
Industrial smoothing screed
Elgood installed 600 m² of smoothing screed to resurface a particularly rough section of the floor. This helped create a more even base before the final epoxy coating was applied, improving the overall finish and performance of the completed industrial floor.
Britdura Solvent Free Highbuild Epoxy Floor Coating
The full 1,600 m² floor was finished with Elgood Industrial Flooring’s Britdura Solvent Free Highbuild Epoxy Floor Coating. The coating was applied by trowel to help ensure an even distribution of resin and a consistent final finish.
This system was well suited to the brief because it provided a cost-effective and hard-wearing industrial floor coating for an engineering environment with forklift traffic.
Dusty Blue, Terracotta and Golden Yellow finish
The industrial floor was finished in Dusty Blue and Terracotta, with Golden Yellow lines. This helped improve the appearance of the engineering facility while providing clearer visual definition across the floor.
Fine slip resistant surface
The coating was finished with a fine slip resistant texture. This provided a safer surface underfoot while still allowing the industrial floor to be cleaned easily using scrubber dryer machines.
Two-phase installation programme
The project was completed in two phases to accommodate other trades working inside the building. The total installation programme lasted seven days, and the floor was ready for use the next day.
Outcome
The completed industrial floor coating provided Wallis Ltd with a durable, practical and visually improved floor for its Nottingham engineering facility:
A 1,600 m² Britdura Solvent Free Highbuild Epoxy industrial floor coating
600 m² of smoothing screed to resurface a particularly rough section
Remedial repairs including hole filling and general making good
A cost-effective solution tailored to variable concrete conditions
A hard-wearing finish suitable for forklift traffic
A Dusty Blue and Terracotta floor finish with Golden Yellow lines
A fine slip resistant surface that can be cleaned using scrubber dryer machines
A two-phase project completed over seven days to accommodate other trades
A completed industrial floor ready for use the next day
By combining dust free preparation, diamond grinding, remedial repairs, smoothing screed and Britdura Solvent Free Highbuild Epoxy Floor Coating, Elgood Industrial Flooring delivered a practical and hard-wearing industrial floor for Wallis Ltd in Nottingham. The finished floor improved the condition, appearance and usability of a heavily worn engineering floor while providing a durable surface suitable for daily industrial use.
