Zenith Flooring was appointed to deliver a large-scale flooring refurbishment for a leading automotive manufacturer.
Covering approximately 18,000m², the project involved extensive substrate preparation, major concrete repairs and the application of a high-performance epoxy coating system. The programme was time-sensitive, requiring careful planning, coordinated resources and efficient delivery around the client’s operational requirements.
The challenge
The size of the installation and the condition of the existing substrate made this a demanding industrial flooring project.
Before the new coating could be applied, extensive repairs were required to restore the floor and create a stable, consistent surface. The works also needed to be completed within a fixed programme to reduce disruption to the wider manufacturing operation.
Zenith developed a structured installation plan that coordinated preparation, repairs, coating application and curing across the 18,000m² area.
Large-scale substrate preparation
The existing floor was shot blasted to remove weak surface material, contamination and any remaining coatings that could affect adhesion.
This mechanical preparation created a clean, textured profile for the subsequent repair and coating systems. Working across such a substantial area required the preparation process to be carefully sequenced, ensuring each section was ready for the next stage without delaying the wider programme.
Extensive floor repairs
Once the substrate had been prepared, Zenith completed a comprehensive programme of concrete repairs.
Approximately 35 tonnes of epoxy mortar and six tonnes of polyester repair materials were used to rebuild damaged areas, fill defects and reinforce the existing floor.
Different repair materials were selected according to the nature of each defect and the required curing time. This enabled the team to address the condition of the substrate while maintaining progress across the site.
The scale of the repair work was essential to the performance of the completed floor. Applying a coating without first correcting these defects would have increased the risk of imperfections and premature failure becoming visible through the new system.
High-performance epoxy coating
Following the completion of the repairs, Zenith applied approximately 10 tonnes of high-performance epoxy coating across the prepared surface.
The system created a durable and uniform finish capable of supporting the demands of a busy automotive manufacturing environment.
Careful control of the application process helped maintain consistent coverage throughout the 18,000m² installation, while the phased programme allowed completed sections to progress through the required curing periods before being returned to service.
Completed ahead of schedule
Through detailed planning, efficient sequencing and close coordination between the installation teams, Zenith completed the project two days ahead of the agreed programme.
Delivering ahead of schedule helped reduce the impact of the works on the client’s operations while still allowing sufficient time for preparation, repairs, coating application and curing.
The completed floor
The completed installation transformed a heavily worn industrial substrate into a consistent, hard-wearing epoxy floor suitable for ongoing automotive manufacturing use.
Across the project, Zenith delivered:
- approximately 18,000m² of refurbished industrial flooring;
- extensive shot blasting and substrate preparation;
- repairs using 35 tonnes of epoxy mortar;
- six tonnes of polyester repair materials;
- 10 tonnes of high-performance epoxy coating; and
- completion two days ahead of schedule.
The result is a durable industrial flooring system delivered at scale, with the preparation, repair work and programme management required for a major automotive facility.
