As part of a long-term refurbishment programme within a world-leading aerospace manufacturing facility in Birmingham, this phase covered approximately 95m² of operational floor space. The works formed Phase 4 of a structured upgrade strategy, following the same specification adopted across earlier areas of the site.
The existing substrate was heavily worn and affected by bolt holes, minor impact damage and surface inconsistencies typical of high-traffic engineering environments. Because the facility remained operational, the solution needed to combine durability, slip resistance and rapid return to service. JD Flooring installed a fast-curing, multi-layer resin high build system designed to withstand mechanical wear, chemical exposure and regular pedestrian movement, while maintaining a professional, clearly demarcated finish suitable for aerospace manufacturing standards.
Following a detailed site survey, our technical team identified widespread surface degradation and a high volume of redundant bolt penetrations across the 95m² area. Access was restricted due to surrounding machinery, meaning large planetary preparation equipment was unsuitable. Therefore, flat bed diamond grinders connected to HEPA-filtered extraction were specified to ensure controlled mechanical preparation in confined working zones.
As with all industrial installations, preparation was the most critical stage of the project. Using flat bed diamond grinding equipment connected to high-powered vacuum extraction, we mechanically removed surface contaminants, weakened laitance and uneven high spots. This ensured the concrete substrate was clean, profiled and ready to accept the resin system.
Once preparation was complete, approximately 300 bolt holes and multiple small impact-damaged areas were repaired using a suitable flexible resin repair compound. Each repair was levelled and feather-finished to maintain surface regularity prior to coating. This meticulous preparation process ensured optimum adhesion and long-term performance, reinforcing the principle that the lifespan of any resin floor is determined primarily by substrate condition and preparation quality.
Following completion of preparation and repairs, installation commenced with the application of the first coat of Polyaspartic high build resin. This fast-curing system was selected specifically to minimise operational disruption while delivering a seamless, durable surface suitable for aerospace manufacturing environments.
After the initial coat had cured, a second high build coat was applied to achieve the required film thickness and surface uniformity. The multi-layer system provided enhanced abrasion resistance and improved longevity under regular foot traffic and equipment movement. A light quartz aggregate was broadcast to improve slip resistance, acknowledging the presence of oils, coolants and routine cleaning regimes common within engineering facilities.
Once curing was complete, a 100mm safety yellow demarcation line was installed around the perimeter of both treated areas. This clearly defined operational zones and reinforced safe pedestrian movement. Due to the rapid curing characteristics of the Polyaspartic system, the floor was ready for use the following day, ensuring minimal disruption to the client’s production schedule.
The client expressed high satisfaction with both the installation process and the finished result. Particular praise was given to the professionalism of the on-site team, strict adherence to the agreed installation schedule, and the minimal disruption caused to operational activities.
The thorough preparation process, cleanliness of the working area and the speed of installation were also highlighted. The completed floor delivered a durable, compliant and clearly defined working environment consistent with aerospace manufacturing standards.
A solvent free epoxy coating applied in two or more coats, building a film thickness of up to 1,000 microns. It is specified for medium duty use where the requirement is a clean, hard wearing surface over sound concrete.
Aggregate is scattered between coats where a slip resistant finish is needed. Anticipated life is 5 to 7 years in light use and 2 to 4 years under moderate use.
| Application | Applied in two or more coats, solvent free |
|---|---|
| Intended Use | Medium duty use |
| Thickness | Up to 1000 microns |
| Chemicals | Some resistance to chemical spillage |
| Slip Resistance | Aggregate can be added to achieve a slip resistant finish |
| Anticipated Life | Light use 5-7 years / Moderate use 2-4 years |
WalesHigh Build Coating
BirminghamHigh Build Coating
KnutsfordHigh Build with Quartz Aggregate
Cheadle HulmeHigh Build Coating
DisleyHigh Build Coating
CheshireHeavy Duty Polyurethane Screed
West YorkshireHigh Build Coating
East YorkshireHigh Build Coating
StaffordshireHigh Build Coating
Tell us how the area is reached, what happens in it and how long it can be closed. We attend, test the substrate, and put a written specification and a fixed price in front of you at no cost.
