Operating within a busy dairy and cheese manufacturing facility in Wrexham, this project involved a comprehensive 350m² industrial resin flooring installation. The client’s existing floor had become severely worn, posing significant slip hazards and making routine hygiene processes increasingly difficult to maintain. Because the facility operates on a demanding daily production schedule, the primary challenge was executing a complete floor refurbishment within a strict three-day window.
The client required a durable, slip-resistant, and hygienic solution that could withstand the rigorous cleaning regimes typical of the food and drink sector. JD Flooring delivered a tailored, rapid-turnaround high build resin system, ensuring the new surface was fully cured and ready to support full dairy production operations by the following day, with zero disruption to their wider supply chain.
Following a thorough site survey, our technical team assessed the 350m² area, identifying a heavily degraded polyurethane screed substrate. In food manufacturing environments, surface integrity is critical to prevent bacterial growth; therefore, complete mechanical removal of the compromised top layer was essential. Given the stringent hygiene and safety demands of the dairy sector, we specified a robust, two-coat high build epoxy resin system.
To directly address the client’s concerns regarding slip hazards in a wet processing area, we recommended incorporating a heavy broadcast of quartz aggregate. This specification delivers a highly textured, slip-resistant profile while remaining non-porous and compliant with food-grade cleaning standards. This approach balanced the need for exceptional traction, long-term durability, and rapid curing within the facility’s constrained three-day operational downtime.
Adhering to the principle that comprehensive preparation dictates the lifespan of any industrial resin flooring installation, our team initiated a rigorous mechanical profiling phase. Utilising an HTC500 triple-headed planetary grinding machine connected to HEPA-filtered vacuum extraction, we systematically removed the failing polyurethane screed to expose a sound, uncontaminated concrete substrate. In restricted zones around structural columns, stainless steel machinery, and perimeter edges, specialist hand-held diamond grinders were deployed to ensure uniform preparation.
Following the grinding phase, the team identified impact damage across the upstands and existing coved skirting. These areas were meticulously restored using a high-strength polyurethane mortar, ensuring a seamless, hygienic transition between the floor and wall. This meticulous attention to substrate repair guaranteed optimal adhesion for the incoming epoxy system.
Upon completion of all mechanical preparation and structural repairs, the installation sequence commenced with the application of a premium, two-pack high build epoxy resin base coat across the 350m² zone. While still wet, this layer was fully blinded with a heavily broadcast, specially graded quartz aggregate to create an aggressive, slip-resistant profile engineered for wet dairy processing environments. Following an overnight cure, the JD Flooring team mechanically brushed and vacuumed the entire footprint to extract all unbound aggregate, leaving a highly textured yet consistent foundation.
A secondary epoxy seal coat was subsequently applied using a precise squeegee method and meticulously back-rolled to ensure optimal film thickness and fully encapsulate the quartz matrix. Concurrently, the existing perimeter coving received two coats of the identical epoxy system, resulting in a continuous, fully watertight hygienic barrier essential for food safety compliance. Thanks to precise scheduling, this fit-for-purpose manufacturing area was fully cured and handed back to the client the next day, perfectly aligning with their resumption of full dairy production operations.
The client was exceptionally satisfied with the completed project, specifically highlighting our ability to deliver a complex flooring upgrade with zero disruption to their core operations. They praised JD Flooring’s strategic approach of executing preparation works during night shifts and completing the main installation over a weekend.
Furthermore, the dairy management team commended our technicians for their professionalism, stringent cleanliness, and adherence to strict food-grade site protocols throughout the project.
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 |
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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.
